Method and system for creating co-layer surface adhesive rule

ABSTRACT

A co-layer surface-adhesive rule (SAR) that has a pre-defined cross-section profile. The co-layer surface-adhesive rule (SAR) has two or more layers, wherein at least one layer is made from flexible material and wherein at least two layers differ one from the other.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a utility patent application being filed in the United States asa non-provisional application for patent under Title 35 U.S.C. §100 etseq. and 37 C.F.R. §1.53(b) and, claiming the benefit of the priorfiling date under Title 35, U.S.C. §119(e) of the United Statesprovisional application for patent that was filed on May 17, 2010 andassigned Ser. No. 61/345,180, which application is incorporated hereinby reference in its entirety. This application is related to and filedconcurrently with: U.S. application Ser. No. 13/108,312 bearing thetitle of FLEXIBLE MATERIAL FOR SURFACE ADHESIVE RULE, filed on May 16,2011 under the attorney docket number 08025.1020; U.S. application Ser.No. 13/108,389 bearing the title of METHOD AND SYSTEM FOR SURFACEADHESIVE RULE TECHNOLOGY, filed on May 16, 2011 under the attorneydocket number 08025.1030; and U.S. application Ser. No. ______, bearingthe title of METHOD AND SYSTEM FOR CREATING SURFACE ADHESIVE RULECOUNTER DIE, filed on May 16, 2011 under the attorney docket number08025.1050, all of which are incorporated herein by reference.

TECHNICAL FIELD

The present disclosure generally relates to die-cutting/creasingindustry, and more particularly the disclosure relates to a system andmethod of manufacturing die-cutting/creasing and preparing pre-treatedcardboards/papers.

BACKGROUND ART

The rapid evolution of trade around the world (globalization) creates asignificant demand for packaging in order to transfer/distribute goodsto different remote areas. The transport of goods may be done by: ship,airplanes, trucks, and so on. The transport of goods may be performedby: the manufacturer; different suppliers; individual persons; etc.Further, a significant demand for different brochures, flyers, etc.,also takes part in trade. The different brochures/flyers may havepre-folds and/or embossing, for example. Embossing such as, but notlimited to Braille writing.

Packaging takes a major role in the marketing today. The package inwhich the goods are packed and presented, in a store for example, maydetermine if the goods will be appealing to a potential buyer in thestore or not. Thus the packaging appearance can have a direct effect onthe sales of merchandise. The brochures, flyers, and so on may alsocontribute to the sales/awareness to a product/service etc.

Henceforth, throughout the description, drawings and claims of thepresent disclosure, the terms package, paperboard box, parcel, box,carton box, cardboard box, brochure, flyers, etc. may be usedinterchangeably. The present disclosure may use the term package as arepresentative term for the above group.

A known preliminary requirement, in order to construct a package, ispreparing or purchasing a pre-treated cardboard and/or paper basedmaterial. Paper based material may be of different types. Exemplarytypes may be: waxed paper, cartridge paper, art paper, etc. Henceforth,throughout the description, drawings and claims of the presentdisclosure, the terms cardboard, card-stock, display board, corrugatedfiberboard, paperboards of different paper based material, foldingboxboard, carton, blanks, and so on, may be used interchangeably. Thepresent disclosure may use the term cardboard as a representative termfor the above group.

The pre-treatment of a cardboard may include the following acts:creating folding lines along the cardboard to ease and provide accuratefolding of the cardboard; piercing the cardboard in different areas;creating embossment in different areas of the cardboard; cutting the rawcardboard into predefined shapes; and so on. Henceforth, thedescription, drawings and claims of the present disclosure the termspre-folded cardboard, and pre-treated cardboard may be usedinterchangeably. The present disclosure may use the term pre-treatedcardboard as a representative term for the above group.

Some common techniques for preparing a pre-treated cardboard include theacts of placing the cardboard between dies. Known dies are: a steel-ruledie and a counter-die. The steel-rule die may include a variety ofdifferent types of dies. Exemplary types of dies can be: a cutting-die;a creasing-die; an embossing-die; a scoring-die; a combination of thedifferent types of dies; and so on. The steel-rule die body is usually ahard-wood-based material. Exemplary hard-wood-based material may be:plywood, maple wood, etc. Other exemplary material may be: plastic,metal, fabric, etc. The body material is required to have ahigh-dimension stability and a high-grade and be without voids or otherimperfections.

Jammed deeply and firmly into a plurality of pre-made slots inside thesteel-rule die's body is a plurality of steel-rules. The pre-made slotshold the steel-rules in place during the production of the steel-ruledie. Further, the pre-made slots support the steel-rule during theoperation of the cutting/creasing/embossing of numerous cardboards. Thesteel-rules are usually cut and bent blades made of hardened steel, forexample. Usually, around the steel-rules, a plurality of ejection(rebound) rubbers need to be placed and glued. Without the ejectionrubber the cardboard may tend to get stuck amongst the steel rules.

The counter-die comprises a body. The body is usually a hard-wood-basedmaterial. Other exemplary material may be: plastic, metal, fabric, etc.Commonly, a plurality of trenches is grooved in the counter-die. Thetrenches location and structure is required to fit precisely to thelocation and structure of the steel-rules of the steel-rule die.

Known common techniques of manufacturing steel-rule dies include theacts of: preparing slots in the die's body (the wood for example) forthe steel-rules. This is commonly done by a station using laser orspecial bandsaw, for example. Next a specialist cuts and bends the steelrule and positions them into the slots in the body. The positioningrequires hammering the steel-rules deeply into the slots. Adjustments ofthe height of the steel-rule protruding from the body of the die areusually required as well. A specialist will then need to glue aplurality of ejection rubbers around the steel-rules.

Known common techniques of manufacturing the counter-dies includeseveral actions. For example, during the production of the counter-dieone or more inexpensive material (inserts) may be associated to thecounter-die's body. The inserts may be associated to the body by screws,nails, re-positional adhesive, etc. The inserts may be made ofphenolic-resin, paper, fabric, for example. The inserts may comprisetrenches in it. The inserts are positioned so that theirgrooves/trenches are aligned/centered with the corresponding steel-rulesof the steel-rule die. The alignment/centering of the inserts is usuallyperformed by a specialist.

A trial cutting/creasing/embossing operation can then be made betweenthe steel-rule die and the counter-die, together with a sheet ofpaper-based material between them, for example. If thealignment/centering is not satisfactory, the specialist detaches theinserts from the counter die and re-positions them. If thealignment/centering is satisfactory, the specialist can groove trenchesin the counter die's body precisely where the trenches of the insetswere and detach the inserts from the body. In alternate embodiments, theinserts with the trenches may be left on the counter die's body and actas the trenches.

SUMMARY OF DISCLOSURE

In the common steel-rule die and counter-die industry, the rulesmaterial (steel, for example) enables the creasing/cutting/embossing ofthe cardboards while having a good sustainability and durability to thenumerous slamming and pressure of the counter die on the steel-rule dieduring the cut/crease/emboss operation. The common rules (usually steelrules) are hammered deep inside the die's body (usually hard-wood-basedmaterial) in order to enable and assure that they will be fixed in placeeven at the harsh operation which can be around a few ton press force(100 ton press for example) in a plurality of directions on the commonrules. Commonly the steel-rules are inserted deep inside the die's body(18 mm, for example). The die's body thus is usually very dense heavyand thick and the grooves in the body, for the common rules, are usuallydeep.

The common steel-rule die and counter-die industry requires a complexoperation and collaboration between different entities. Entities may bedifferent companies, for example. For example, if a client requests acertain package to be made for him, the following scenario usually maytake place in the common industry:

(a) A first entity may be a company that prepares a sample of aprototype of the requested package.

(b) This prototype needs to be transport to the client for approval,and, if the client does not approve. This step needs to be repeateduntil the client is satisfied.

(c) Next an order for a common steel-rule die and counter-die needs tobe made. This step may be performed by a different entity (a secondentity). The second entity needs to acquire die body (wood for example),steel-blades, and insert-material. People skilled in the art ofdie-making will need to: groove the die's body; cut and bend thesteel-rules; hammer the steel-rules in place; glue the ejecting rubbers;attach the insert to the counter-die body; center and groove thecounter-die's trenches in precise required location; etc.

(d) Next, the common steel-rule die and counter-die will need to betransferred (by truck, ship, airplane, etc.) to a third entity. Thethird entity will need to: install the received common steel-rule dieand counter-die to a press/die machine; set-up the machine and fine tuneit; insert cardboards; and gather the pre-treated cardboards.

(e) The common steel-rule die and counter-die will then need to bestored for future use. The storage is usually a big warehouse since thecommon steel-rule die and counter-die are very big and heavy.

(f) Lastly the pre-treated cardboards need to be sent to the client (bytruck, ship, airplane, etc.).

Thus, those skilled in the art will appreciate that the commonsteel-rule die and counter-die industry requires different craftsmen,long time leads for production, relies heavily on transportation,consumes tons of wood and/or tons of steel, demands huge storage areas,generates environmental pollution, and involves a complex cooperationbetween different companies, etc.

The above-described deficiencies in common die-cut/crease/embossindustries do not intend to limit the scope of the inventive concepts inany manner. They are merely presented for illustrating an existingsituation.

Among other things, the present disclosure provides a novel system,apparatus and method for a novel surface-adhesive-rule technology(SART). In the novel surface-adhesive-rule technology (SART), the rulesmay be adhered to the surface of the body of the die. Thus, there is noneed to groove the body, place precisely and hammer the rules insidetrenches of the die's body. In exemplary embodiments, the surface may besmooth; however, it will be appreciated that in alternate embodiments,the surface may not be smooth. For example the surface may be: scraped,laser burned, etc. The rules of the surface-adhesive-rule technology(SART) may include a variety of different types of rules. Exemplarytypes may include: cutting rules; creasing rules; embossing rules; etc.Henceforth, throughout the description, drawings and claims of thepresent disclosure, the terms cutting rules, creasing rules, embossingrules, etc. may be used interchangeably. The present disclosure may usethe term rule as a representative term for the above group.

The novel surface-adhesive-rule technology (SART) enables themanufacture of a complete surface-adhesive-rule die with the creation ofits surface-adhesive rules (SAR) by one machine. Thus, advantageously,utilizing the SART alleviates the requirement for complex operationbetween different companies. Furthermore, another advantage of thesurface-adhesive-rule technology (SART) is that it may be fullyautomatic and controlled by a computer, for example. Thus, no skilledcraftsmen (specialists) are required in the manufacturing of a die. Inaddition, the surface-adhesive-rule technology (SART) alleviates theneed for warehouse space because the layout and all information relatedto the surface-adhesive-rule die may be stored on a computer or otherstoring medium such as CDROM, flash disc, etc. Thus the novelsurface-adhesive-rule technology (SART) advantageously provides alow-cost, easy to use, friendly to the environment, and a shortenedlead-time for production of a full surface-adhesive-rule die and counterdie.

In exemplary embodiments, including some of the embodiments described inthe present disclosure, the surface-adhesive rules (SAR) of thesurface-adhesive-rule technology (SART) may be made offlexible-material. The flexible material may be liquid or gel likematerial. The flexible-material may include one or more different typesof polymers or even different combination of differing types ofpolymers. Exemplary polymers that may be used may include: polyester,polyamide, polycarbonate, polyurethane, acrylic, polypropylene,polyethylene, etc. Furthermore, the flexible-material may include one ormore additives. These additives may include, but not limited to: silica,ceramics, metal, various fibers, different fillers, etc.

In exemplary embodiments, the flexible material of the surface-adhesiverules (SAR) may comprise several layers (co-layer). Each layer may bemade of different materials. Each layer may also have a different:shape; cross-section; width; comprise different polymer types and/oradditives; etc. Each layer may have a different required attribute. Forexample the lower layer may be required to have better adhesiveattributes, the highest layer may be required to have more elasticattributes, and so on.

The disclosed novel surface-adhesive rules (SAR) may have a strongenough sustainability, firmness, inside-cohesion, robustness, and/orlifespan to withstand the pressure and harsh operation of high pressurepress force (1-10 ton, for example) in one or more directions on thesurface-adhesive rules during the cutting/creasing/embossing operationof the cardboards.

The flexible material (the liquid or gel like material) of the SAR mayhave additional attributes (attributes). Exemplary attributes mayinclude the ability of the flexible material to reserve the requiredsurface-adhesive rule (SAR) profile while drawing the SAR on thesurface-adhesive-rule die's body (SARD) surface. Wherein the reserve therequired surface-adhesive rule (SAR) profile is within plus minus a fewpercentage (between 5-15 percent) from the profile of an orifice of anozzle through which the flexible material is deposited (drawn) as a SARfor a period of few seconds to few hours, for example. Other exemplaryembodiments the reserve the required surface-adhesive rule (SAR) profilemay be plus minus a 10-30 percentage from the shape of the profile for afew minutes to tens of minutes, for example.

The ability to reserve the required surface-adhesive rule (SAR) profilewhile drawing the SAR may be achieved by attributes of the flexiblematerial. Exemplary attributes of the flexible material such as, but notlimited to: thixotropic, pseudo plastic, hardness, high viscosity, etc.The attributes required to enable reserving the requiredsurface-adhesive rule (SAR) profile may be achieved by the compositionof ingredients. Exemplary composition of ingredients may comprise: 7-50percent additives such as but not limited to: silica, filers, etc. Inother exemplary embodiments the range of the additives may be 10-30percent. Other exemplary embodiments of composition of ingredients maycomprise 60-85 percent polymer. Exemplary polymers such as but notlimited to: SPF 918, polyurethane, etc. In yet other embodiments acombination of the above may be used.

Other exemplary attributes may include: flexibility, viscous, cohesive,brittle, tacky, erectness, spreading capabilities, required thickness,etc. Drawing the SAR on the SARD may comprise the following actions:create SAR; lay SAR; and adhere SAR on the surface of the SARD's body.The drawing of the SARs may be done in a continuous motion, in asegmented motion, and/or a combination of both motions. The flexiblematerial of the SARs ingredients and the ratio between them mayinfluence the different attributes of the flexible material. Exemplaryingredients may include: different polymers, silica, ceramics, fillers,fiber, etc. Exemplary ratios of combinations of different ingredientsmay be for UV curing (i.e., see tables 1, and 2) and for thermal curing(i.e., see tables 3, 4 and 5):

Ingredient % Weight Exemplary supplier SPF 918 81.4 RAHN AEROSIL R-97213.0 EVONIK Genocure LTM 2.8 RAHN Genocure LBC 2.8 RAHN

TABLE 2 Ingredient % Weight Exemplary supplier SPF 918 80.9 RAHN AEROSILR-812 13.5 EVONIK Genocure LTM 2.8 RAHN Genocure LBC 2.8 RAHN

TABLE 3 Ingredient Weight Exemplary Supplier U-1050 100 Polymer GvulotEPC-238 34-45 Polymer Gvulot AEROSIL R-972 100 EVONIK

TABLE 4 Ingredient Weight Exemplary Supplier U-233 100 Polymer GvulotEPC238 34-45 Polymer Gvulot CabOsil M5  24 CABOT

TABLE 5 Ingredient Weight Exemplary Supplier U-233 100 Polymer GvulotEPC238 34-45 Polymer Gvulot Aerosil R-812  24 EVONIK

In some embodiments the flexible material of the SAR may be:thermoplastic polymers, thermosetting polymers, metal, a combination ofthem, and so on. Exemplary flexible material may comprise: Polyurethane,having a hardness of 60-99 shore A, preferably, 80-99 shore A orPolypropylene, etc. Optionally, the viscosity of the material asdeposited (drawn) may be between 1,000 cps and 145,000 cps, preferablybetween 17,000 cps and 80,000 cps, etc.

Yet in some embodiments, the SAR may be a cutting SAR. According tothese embodiments, the edges of the SAR may be milled (scraped) in orderto form a sharpened edge adapted for cutting, for example. The millingmay be done by mechanical or optical equipment. In these embodiments,the SARs may be have a hardness of 85 shore A and more or 35 shore D andmore. Exemplary materials that may be used are: polymers loaded withglass fiber, carbon fiber, Kevlar fiber or fillers like silica, metal,carbon black etc.

In exemplary embodiments, the SAR (surface-adhesive rule) profile/shapemay comprise different attributes. Exemplary attributes of the SARcross-section may be: a wide base, a non-symmetrical shape, a coneshape, straight shape, and different combination of them. The shape andattributes of the SAR may be determined according to different requiredparameters. These parameters may include, but are not limited to: thelayout of the surface-adhesive-rule die (SARD); the distance betweendifferent SARs; the direction from which harsh forces will strike theSARs; the adhesive requirements; etc. The SART (surface-adhesive-ruletechnology) may enable the SARs to have non-standard sizes if required.

In exemplary embodiments, including some of the embodiments described inthe present disclosure, the surface-adhesive-rule die's (SARD) body maybe made of flexible film. The flexible film may include one or moretypes of polymers. Exemplary polymers that may be used include, but arenot limited to: polyester, polyamide, polycarbonate, and/or acombination of these polymers or others. Furthermore, the flexible filmmay include one or more additives. These additives may include, but notlimited to: silica, ceramics, metal, different fillers, etc. Exemplaryembodiments of the flexible film may comprise several layers(co-layers). Each layer may be constructed of a different material.

The surface-adhesive-rule die's (SARD) body may be associated with,connected to, or joined with a substrate made from material other thanflexible film. Materials such as, but not limited to, metal, wood, etc.Furthermore, the surface-adhesive-rule die's (SARD) body may have a flatshape, cylindrical shape or any other shape. In addition, the SARD'sbody may be flexible such that it can change its shape, for example fromflat to cylindrical so it can be wrapped around a drum, for example.

The flexible film of the SARD's body may have a strong enoughsustainability, firmness, inside-cohesion, robustness, and/or lifespanto withstand the pressures and harsh operation which can be around a fewton press force (1-10 ton, for example) in one or more directions duringthe cutting/creasing/embossing operation of the cardboards. In otherexemplary embodiments, the SARD's body may be made of material otherthen flexible film, and/or a combination of them. Furthermore, thesurface-adhesive-rule technology enables working without the need ofejection (rebound) rubber around the surface-adhesive rule.Advantageously, this aspect of the various embodiments saves time,money, and rubber material.

The surface-adhesive-rule technology may comprise a novel flexiblesurface-adhesive-rule counter die (SARCD). The SARCD body may compriseflexible-counter film. The flexible-counter film may include one or moretypes of polymers. Exemplary polymers that may be used include, but arenot limited to: polyurethane, EPDM (ethylene propylene diene Monomerrubber), NBR (Nitrile butadiene rubber), acrylic rubber, siliconerubber, SBR (Styrene-Butadiene-Rubber) etc. Furthermore, theflexible-counter film may include one or more additives. These additivesmay include, but not limited to: silica, ceramics metal, fillers,various fibers, slip agent, carbon black, talc, etc. Exemplaryembodiments the flexible-counter film may comprise several layers. Eachlayer may be made of different materials.

The surface-adhesive-rule counter die's (SARCD) body may be associatedwith, joined to or connected to a material other then theflexible-counter film. These materials may include, but not limited tometal, wood, PET (Polyethylene terephthalate) film, sponge material(with open or closed cells), etc. For example, the flexible-counterfilms may be associated with, joined to or connected to a spongematerial, and the sponge material may be associated with, joined to orconnected on its other side to a PET (Polyethylene terephthalate) filmbase, and so on. Furthermore, the surface-adhesive-rule counter die's(SARCD) body may have a flat, cylindrical or any other shape. Inaddition, the SARCD's body may be flexible such that it can change itsshape, for example from flat to cylindrical so it can be wrapped arounda drum, for example. The flexible-counter film may have a strong enoughsustainability, firmness, inside-cohesion, robustness, and/or lifespanto withstand pressure and harsh operation. The surface-adhesive-rulecounter die's (SARCD) may be supplied/sold as a SARCD body, and/or as aSARCD body associated with, joined to or connected to a drum or a flatbase. As a non-limiting example, the SCARD body associated with a flator drum base by molding, coating, attachment by grippers, etc.

The flexible-counter film may have additional attributes. Examples ofthese additional attributes may include, but are not limited to:flexibility, required thickness, resilience, required hardness,dimension stability, coefficient of friction, sustainability,inside-cohesion, robustness, life span, sponge attribute, wear-outresistance, etc. Exemplary surface-adhesive-rule counter die (SARCD) mayhave a body that is comprised of a flexible-counter film made ofpolyurethane at a thickness of a few mm (1.1-3.7 mm, as a non-limitingexample) with a hardness of a few tens of shores (20-70 shore, as anon-limiting example).

Exemplary embodiments of the flexible-counter film may be comprised ofseveral layers. Each layer of the flexible-counter film may be made fromor comprise different ingredients. Further, each layer of theflexible-counter film may have different attributes. As a non-limitingexample, the lowest or bottom layer may be comprised of a material withattributes that: have a high friction coefficient, are tacky, have anaffinity, and/or include a degree of firmness. Further, the highest ortop layer of the flexible-counter film may be comprised of a materialwith attributes that: have a high resilience, have a degree offlexibility, and/or are resistant to wearing out.

Even further, an intermediate layer of the flexible-counter film may becomprised of a material with attributes that provide sponginess orcompression, etc. In some exemplary embodiments, the flexible-counterfilm may also be comprised of a lattice with a pre-defined density ofone or more different fibers. Exemplary fibers in the lattice mayinclude, but are not limited to, metal fibers, carbon fibers, etc. Inother exemplary embodiments, the flexible-counter film may be notched.The notches may be made in a variety of manners such as but not limitedto by a laser.

The SARCD flexible-counter film's ingredients and the ratio between themmay influence the different attributes of the flexible film. Exemplaryingredients may include, but are not limited to: different polymers,silica, ceramics, fillers, fiber etc.

The surface-adhesive-rule technology (SART) may provide a novel surfaceto the flexible surface-adhesive-rule counter die's body (SARCD). Inexemplary embodiments, the surface of the flexible SARCD's body may be ablank surface. A blank surface may be defined as a surface with notrenches or pattern/layout. The flexible-counter film may be such thatit adapts itself to the SAR (surface-adhesive rule) that it willencounter. This characteristic has the advantage of alleviating the needfor resources and time that is required in the creation of trenches on acounter-die.

Further, the surface of the flexible surface-adhesive-rule counter die's(SARCD) body may return to a blank surface after the dies (SARD andSARCD) detach from each other (resilience attribute). Thus, the flexibleSARCD may be used for different surface-adhesive-rule dies (SARD). Thischaracteristic that can be employed in various embodiments also resultsin reducing the cost and production time for the SARCD. In otherexemplary embodiments, the SARCD material may remember thepattern/layout due to the press, this attribute may be achieved usingthermoplastic material, for example.

In alternate exemplary embodiments, the surface of the flexible SARCDbody may include one or more trenches. The trenches may be created usinga variety of different techniques. Exemplary techniques for creating thetrenches may comprise: using a laser, drawing negative, extrusion,gnawing, molding, coating, etc. The SARCD may also be created using avariety of different techniques. Techniques for creating the SARCD mayinclude, but not limited to: molding, coating, press/injection molding,a combination of them, etc. More information on the different techniquesof creating the SARCD is disclosed below in conjunction with thedescription of FIGS. 16-18.

The surface-adhesive-rule technology (SART) enables a user to create afine crease in the cardboard. This has been experimentally tested andverified by the applicants. The creases achieved by use of the SARTexceed current industry standards and as such, it may result in creatinga new and higher (finer) standard. Furthermore, the SART improves thequality of the pre-treated cardboard crease's surface. Theseimprovements may include significantly reducing the number and severityof ply-cracks, for example. Thus, the SART performs at a level thatexceeds the present industry capabilities and standards.

In addition, the SART allows for new shapes of packages to be createdand at a higher aesthetic quality. This also has been experimentallytested and verified by the applicants. The SART enables a user to createnew and different shapes of creasing/cutting/embossing and differentalignment of the creasing/cutting/embossing on the cardboard. Forexample, the SART enables: the pre-treated creasing to be much morerefined; reduces ply-cracks and reduces the tearing of the cardboard;etc.

The flexible film of the SARD's body and/or the flexible-counter film ofthe SARCD's body, may be relatively immune to a changes in roomparameters and over a wider range of room parameters. For instance,SARD's body and/or SARCD's body provide consistent results when roomparameters such as, but not limited to, temperature, humidity, light,etc. vary or over a wide range of these parameters.

In exemplary embodiments of the present disclosure, the surface-adhesiverules (SAR) may be bonded to the surface of the flexiblesurface-adhesive-rule die's body by adhesion. Exemplary adhesiontechniques may include, but are not limited to, using anintermediated-adhesive material between the SAR and the flexible SARDbody's surface. The intermediated adhesive material used may include,but is not limited to: adcote 811 of DOW company, 238A+catalyst ofMORCHEM company, etc. Other exemplary embodiments of adhesion may beachieved by adhesive attributes of the SAR and the surface of theflexible SARD's body materials. Yet, in other exemplary embodiments, acombination of these two, as well as other techniques may beimplemented. Adhesive attributes may include, but are not limited to:epoxy, oligomer, silicone acrylate oligomer, adhesion promoter,photoinitiator.

Exemplary embodiments of the present disclosure provide a method andsystem for bonding the SARs to the surface of the flexible SARD's bodyduring the course of making the surface-adhesive-rule die (SARD) withthe creation of its surface-adhesive rules (SAR) simultaneously. Thesurface adhesive method and system may comprise: one or morepre-adhesive-treatment methods and systems; one or more adhesivesubstances; one or more adhesive spreading/laying of the adhesivesubstances; one or more curing techniques; one or morepost-adhesive-treatments; and so on.

The type of the surface adhesive method and system utilized may bedetermined based on a variety of parameters. These parameters mayinclude, but are not limited to: the SAR material; the material of thesurface of the SARD's body; the combination of the SAR material and thematerial of the surface of the SARD's body; time requirements of thesurface-adhesive-rule technology (SART); and so on.

Different pre-treatment(s) may be done or applied before drawing SARs.Exemplary pre-treatments that can be applied prior to the drawing mayinclude, but are not limited: different primers and primer techniques;Ozone-shower; high voltage electric cord; electron beam; plasma;flaming, etc. In exemplary embodiments, illuminating the flexible SARD'sbody with UV light can be performed as a pre-treatment before laying andadhering the surface-adhesive rules (SAR), for example.

In an exemplary embodiment, the intermediated-adhesive material may beplaced, spread, sprayed, coated, painted or otherwise placed onto thesurface of the flexible SARD body before the laying of the SARs. In analternate embodiment, the intermediated-adhesive material may be placed,spread, sprayed, painted or otherwise placed on the surface of theflexible SARD's body during the drawing of the SARs. Theintermediated-adhesive material may be placed, spread, sprayed, paintedor otherwise placed on the surface of the flexible SARD's body indifferent methods and systems. Exemplary methods and systems may be:spreading the intermediated-adhesive material by an application headassociated with or controlled by a leading mechanism.

The novel surface-adhesive-rule technology (SART) enables a completesurface-adhesive-rule die (SARD) to be automatically created, whilesimultaneously drawing its plurality of surface-adhesive rules (SARs).Exemplary embodiments of the system and method of thesurface-adhesive-rule technology may include a rule-drawer.

The rule-drawer may operate to automatically draw the surface-adhesiverules (SARs) onto the surface of the flexible surface-adhesive-rules die(SARD) at the desired locations. The process of drawing the rules maycomprise one or more of the following actions: create the SAR; lay theSAR; adhere the SAR onto the surface of the SARD's body. The drawing ofthe SARs may be done in a continuous motion, in a segmented motion,and/or a combination of both motions as well as a variety of othertechniques.

An exemplary embodiment of a rule-drawer may comprise: one or moredrawing-heads, a controller, and a leading mechanism. The drawing-headmay be an automatic drawing-head associated with the leading mechanism.The leading mechanism, under the control of the controller may operateto move elements of the drawing-head to different locations and indifferent directions, for example. The leading mechanism may be amechanical arm, one or more rails, etc. The controller may control thedrawing head as well as the leading mechanism, for example. Forinstance, the controller may operate to cause the leading mechanism tomove the drawing head to a desired location, then trigger the drawinghead to begin drawing.

The controller may be integral to a computer (such as software, firmwareetc. Software may be embodied on a computer readable medium such as aread/write hard disc, CDROM, Flash memory, ROM, or other memory orstorage, etc. In order to execute a certain task a software program maybe loaded to an appropriate processor as needed) or operated by acomputer, for example. As a non-limiting example of the controller beingintegral to a computer, the computer may be loaded with a jobdescription. The job description may include: the type of thesurface-adhesive rules (SAR), the type and thickness of the cardboard,the layout of the surface-adhesive-rule die (SARD), etc. The layout ofthe SARD may include, the placement of each SAR and its type, forexample. According to the layout of the SARD, the controller may commandand automatically control the leading mechanism of the rule-drawer fordrawing the SARs on the SARD's body. The controller may control othermodules of the surface-adhesive-rule technology (SART). Thus, exemplaryembodiments of the present disclosure may include the above-describednovel method and system of creating an automatic direct-computer-to-die(DCTD) surface-adhesive-rule technology (SART).

The computer of the SART may further comprise a stored look-up table.The stored look-up table may comprise different information. Exemplaryinformation may include, but is not limited to: information regardingthe surface-adhesive rule's profile according to required cardboardthickness; the required cardboard length; the cardboard coefficient offriction (COF); the information regarding the required ingredients forthe flexible material for a required cardboard; the informationregarding the required ingredients for the flexible material for arequired function (cutting/creasing/embossing); the profile of SAR; thenozzle type; and so on.

In an exemplary embodiment, the drawing-head or drawing-heads of therule-drawer may comprise a cartridge. Although the description may referto a single drawing-head, it should be appreciated that in variousembodiments, more than one drawing head may be utilized. The cartridgeof the drawing-head may contain flexible material. The drawing-head mayfurther comprise a nozzle with one or more predefined orifice shapes.The orifice shapes may be selected according to a required profile ofthe surface-adhesive rules (SAR), for example. The drawing-head mayfurther comprise a pressure-actuator. The pressure-actuator may be usedto dispense the flexible material out of the cartridge and through thenozzle's orifice toward the required placement on the surface of thedie's body thereby creating the surface-adhesive rule and die.

The pressure-actuator employed in various embodiments may be ofdifferent types. Exemplary types of the pressure-actuator may include,but are not limited to: an air-pump actuator, a screw-pump actuator, apiston actuator, an electrical pump actuator, a cogwheel actuator, aninject actuator etc. Exemplary embodiments of a pressure-actuator maycomprise a combination of one or more types of actuators. There may beone or more pressure-actuators associated with one or more modules ofthe rule-drawer, for example. In exemplary embodiments, thepressure-actuator may have suction capabilities or functionality aswell.

The nozzle of the drawing-head may have one or more orifices. Theorifice may determine the surface-adhesive rule profile/shape or may beselected to obtain a desired profile/shape. The orifice may be locatedat the bottom of the nozzle, at the side of the nozzle, on an edge ofthe nozzle, or a combination of multiple placements, etc. In exemplaryembodiments, the nozzle may be quickly and easily disassembled ordetached from the drawing-head and a different nozzle may be assembledor attached to the drawing-head. The inside of the nozzle and/or orificemay have a coating that operates to reject or repel the flexiblematerial. Advantageously, this characteristic helps to prevent cloggingor blockage, either partial or complete, of the orifice. The shape andplacement of the orifice may be determined according to differentcriteria. Exemplary criteria may include, but is not limited to:adhesive requirements of the SAR to the surface of the SARD's body; thedrawing-termination technique used; the required surface-adhesive ruleprofile; and so on.

During the drawing of a SAR the nozzle may be placed at a predefinedangle and height from the surface of the SARD's body, according tocommands from the controller, for example. The angle and height of thenozzle may be determined according to different criteria. Exemplarycriteria may include, but is not limited to: orifice location; theflexible material of the SAR; the distance from an adjacent SAR; and soon. In exemplary embodiments, the angle and height may change during thedrawing of the SARs. In exemplary embodiments, the flexible material maybe ejected from the orifice in a “spitting” manner, near a corner forexample.

The cartridge may be implemented in a variety of techniques. Anexemplary embodiment of a cartridge may be a cylindrical shape with aspecific volume capacity (e.g. 30-800 cc volume). In an alternateembodiment, the cartridge may be in a predefined shape, similar to theshape of the nozzle's orifice, for example. Further, in exemplaryembodiments, the cartridge may be associated with or fed from a largervolume container, which can load the cartridge with flexible material atpredefined times, continuously and/or when needed. In exemplaryembodiments, a mixer may be associated with the cartridge. The mixer maymix the flexible material inside the cartridge at predefined times,continuously and/or when needed. The mixer may further comprise aheater, for example.

The inside of the cartridge may have a coating that operates to rejector repel the flexible material. Advantageously, this characteristicpromotes to flow of the flexible material toward the nozzle. Inexemplary embodiments, there may be one or more cartridges workingtogether on the drawing of a SAR, or on the creation of different SARs,and so on. An exemplary embodiment of a multiple-compartments cartridgemay contain, separately, one or more ingredients of the flexiblematerial. In an alternate embodiment, each compartment may comprise adifferent flexible material, for a different layer of the co-layer, forexample.

In alternate embodiment the co-layer may be created in phases. It shouldalso be appreciated than in some embodiments, a bank of cartridges mayutilized to house different ingredients and flexible materials and, thecontroller or rule-drawer may operate to select one or more ingredientsto be mixed, or different materials to be ejected through the nozzledepending on the particular requirements. For example, cartridges mayinclude various additives that can provide different characteristics tothe materials being applied. If quick drying is required in a particularapplication, additives may be pulled from a cartridge that may providesuch a characteristic. Likewise, different pigmentations can beutilized, different levels of viscosity, etc., can be obtained in realtime by the controller controlling the volume of particular additives orsubstances from the cartridges. In some embodiments, a heating elementmay also be utilized to heat the content of the cartridges to a desiredtemperature.

The cartridge may further comprise a combiner. In exemplary embodiments,the combiner may combine the different ingredients and/or flexiblematerial, for example. The combiner may comprise a slot or an aperturethrough which the combined material may be output. The controller of therule-drawer for example, may control the quantities of each component,for example. This can be accomplished in a variety of manners such ascontrolling the flow-rate from a cartridge by adjusting the size of anopening valve from the cartridge, the amount of pressure applied to thecartridge, etc.

In an exemplary embodiment, the drawing-head may further comprise one ormore adhesive-cartridges and an adhesive-nozzle that may spread/sprayadhesive substance on the required areas.

In exemplary embodiments the controller, of the rule-drawer for example,may be responsible to control and synchronize the velocity of theleading mechanism of the rule-drawer to the placement and phase of theSAR drawing process. For example, at the beginning of the drawing of thesurface-adhesive rule, the velocity of the leading mechanism may beslower than the velocity at the middle of the drawing of thesurface-adhesive rule.

In some embodiments, the controller may be responsible for controllingand synchronizing the amount of pressure to be imposed by thepressure-actuator on the flexible material according to the placementand phase of the SAR drawing process. For example, at the beginning ofthe drawing of the surface-adhesive rule less pressure may be imposedthen the imposed pressure at the middle of the drawing of thesurface-adhesive rule.

In exemplary embodiments, the controller may be responsible forcontrolling and/or synchronizing the amount of pressure to be imposed bythe pressure-actuator and the velocity of the leading mechanismaccording to a flow index of the flexible material. The flow index maybe the amount of flexible material that is output through the nozzle'sorifice at a predetermined time with a predetermined pressure, forexample. The flow index may be influenced by the different attributes ofthe flexible material. Attributes such as, but not limited to:viscosity, thickness, tackiness, size of particles, a combination of anyof these attributes as well as others.

In an exemplary embodiment, the leading mechanism may move in aplurality of directions on one or more axes. For instance, the leadingmechanism may move in multiple directions along the X, Y and/or Z axes.In an alternate embodiment, the leading mechanism may move only alongtwo axes, such as the X and Y axes. Exemplary embodiments of thesurface-adhesive-rule technology may further comprise a conveyor onwhich the body of the SARD is associated with during the process. Theconveyor may move in multiple directions along one or more axes and/orin a circular direction, for example. The controller may control theconveyor velocity and direction of movement, for example. In analternate embodiment, the surface-adhesive-rule technology may furthercomprise a drum on which the SARD may be positioned. The controller maycontrol the drum velocity and direction of movement, for example.Further, it will be appreciated that a combination of a moving leadingmechanism for moving the drawing-head and a mechanism for moving theSARD may be employed. For instance, the leading mechanism may move thedrawing head in multiple directions on the X axes while the conveyormoves the SARD in multiple directions on the Y axes. Other combinationsare also anticipated.

Exemplary embodiments of the present disclosure may further implementdifferent hardening techniques. The hardening techniques may include,but are not limited to: temperature treatment, light curing (UV, IR,visible light), chemical curing, etc. In some exemplary embodiments, theflexible material may comprise thermosetting polymers and may behardened by heating, for example. Alternatively or additionally, theflexible material may comprise thermoplastic polymers and hardening ofthe flexible material may be accomplished by cooling the material, forexample. Some flexible materials may include photo-initiator ingredientsthat enable curing by UV illumination, for example. In other exemplaryembodiments, the material may be cooled or harden by itself. In yetother exemplary embodiment, the flexible material may be hardened byelectron beam.

Exemplary embodiments of the present disclosure may comprise a methodand apparatus that will isolate the flexible material that has not yetbeen placed (in the cartridge and nozzle, for example) from the originof the hardening energy. A divider may be placed between the origin ofthe hardening energy and the cartridge/nozzle at the time of hardening,for example.

In some exemplary embodiments, the rule-drawer may further comprise aflow-intermissioner. The flow-intermissioner may be passive, active, ora combination of both. The flow-intermissioner may be implemented as anapparatus, a method, or a combination of both. The flow-intermissionermay, when required, stop/pause the output of the flexible materialduring the drawing of the surface-adhesive rules. The controller maycontrol the operation of the flow-intermissioner. Exemplary embodimentsof the flow-intermissioner may be implemented as different shutters.There may be one or more shutters. The shutter may be associated withone or more modules of the rule-drawer. Exemplary shutters may include,but are not limited to: a knife, an air-knife, a plug, a stopper, etc.

Exemplary embodiments of a flow-intermissioner may include a method inwhich the nozzle is spun sharply around its center while thepressure-actuators stop outputting the flexible material, for example.The method may further comprise adding certain ingredients that willaccelerate the breaking/cutting of the flexible material (brittleattribute) at the moment of required termination. Exemplary ingredientsmay include, but are not limited to: silica, air bubbles, water drops,etc. Other embodiments may implement suction actions.

The surface-adhesive-rule technology (SART) may further comprise aself-maintained-cleaning mechanism. The self-maintained-cleaningmechanism may be a part of the rule-drawer, such as an additionalcartridge that stores cleaning material, for example. In other exemplaryembodiments, the self-maintained-cleaning mechanism may be external tothe rule-drawer. The self-maintained-cleaning mechanism may work atpre-defined times and/or when needed.

Other exemplary embodiments of the surface-adhesive-rule technology(SART) may be implemented using magnetic forces. Exemplary methods ofconstructing a die may be by bonding SARs to the body of the SARD bymagnetic forces. In some embodiments, small pieces of magnetic materialmay be deposit on the SARD's body and attracted to it by magnetic force.An adhesive may be added between the magnetic material and body.Exemplary sizes of the pieces of the deposited magnetic material, may beabout 1 mm on each side, for example. The pieces of material may bedeposited adjacent to each other, so as to form a desired layout ofSARs. In some embodiments, the SARD body may include a magnetic forceonly on the desired layout, for example. Exemplary peel strength betweenthe pieces of material and the body may be about 13 gr/mm².

Yet other exemplary embodiments of the SART (surface-adhesive-ruletechnology) may be implemented by coating the surface of the SARD's bodywith a low surface tension material and the locations where SARs are tobe formed are coated with a high surface tension material. The flexiblematerial may be deposited onto the body of the die. Due to the highsurface tension material at the locations of the SARs, the flexiblematerial may coalesce from the low surface tension areas to the highsurface tension areas. This characteristic creates surface-adhesiverules at the desired locations. Optionally, the material may bedeposited only on areas surrounding the high surface tension areas. Insome embodiments, the SARs may then be hardened and/or adhered to thedie.

Unless otherwise defined, all technical and/or scientific terms usedherein have the same meaning as commonly understood by one of ordinaryskill in the art to which the disclosure pertains. In case there is aconflict in the definition or meaning of a term, it is intended that thedefinitions presented within this specification are to be controlling.In addition, the materials, methods, and examples that are presentedthroughout the description are illustrative only and are not necessarilyintended to be limiting.

Reference in the specification to “one embodiment” or to “an embodiment”means that a particular feature, structure, or characteristic describedin connection with the embodiment is included in at least one embodimentof the disclosure, and multiple references to “one embodiment” or “anembodiment” should not be understood as necessarily referring to thesame embodiment or all embodiments.

Implementation of the method and/or system of embodiments of thedisclosure can involve performing or completing selected tasks manually,automatically, or a combination thereof. Moreover, according to actualinstrumentation and equipment of embodiments of the method and/or systemof the disclosure, several selected tasks could be implemented byhardware, by software or by firmware or by a combination thereof andwith or without employment of an operating system. Software may beembodied on a computer readable medium such as a read/write hard disc,CDROM, Flash memory, ROM, etc. In order to execute a certain task, asoftware program may be loaded into or accessed by an appropriateprocessor as needed.

These and other aspects of the disclosure will be apparent in view ofthe attached figures and detailed description. The foregoing summary isnot intended to summarize each potential embodiment or every aspect ofthe present disclosure, and other features and advantages of the presentdisclosure will become apparent upon reading the following detaileddescription of the embodiments with the accompanying drawings andappended claims.

Furthermore, although specific embodiments are described in detail toillustrate the inventive concepts to a person of ordinary skill in theart, such embodiments are susceptible to various modifications andalternative forms. Accordingly, the figures and written description arenot intended to limit the scope of the inventive concepts in any manner.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the present disclosure will be understood andappreciated more fully from the following detailed description, taken inconjunction with the drawings in which:

FIGS. 1 a-b are simplified block diagrams illustrating an exemplaryportion of a prior art die;

FIG. 2 a-b are schematic illustrations of simplified block diagrams withrelevant elements of an exemplary surface-adhesive-rule die (SARD),according to exemplary teaching of the present disclosure;

FIGS. 3 a-f are schematic illustrations a plurality of simplifieddiagrams with relevant elements of exemplary surface-adhesive-rule (SAR)profiles, according to exemplary teaching of the present disclosure;

FIG. 4 depicts a schematic diagram with relevant elements of anexemplary surface-adhesive-rule technology (SART) system in accordancewith some exemplary embodiments of the present disclosure;

FIG. 5 depicts a schematic diagram with relevant elements of anotherexemplary surface-adhesive-rule technology (SART) system for producing adie in accordance with some exemplary embodiments of the presentdisclosure;

FIG. 6 depicts a schematic diagrams with relevant elements of anexemplary nozzle and cartridge of a rule-drawer, according to exemplaryteaching of the present disclosure;

FIGS. 7 a-b are schematic illustrations of simplified diagrams withrelevant elements of an exemplary nozzles and cartridges of arule-drawer, according to exemplary teaching of the present disclosure;

FIGS. 8 a-f are schematic illustrations of a plurality of simplifieddiagrams with relevant elements of exemplary pressure actuators of arule-drawer, according to exemplary teaching of the present disclosure;

FIGS. 9 a-b are schematic illustrations of different co-layer creations,according to exemplary teaching of the present disclosure;

FIGS. 10 a-d are schematic illustrations of a flowchart showing relevantacts of an exemplary method of a drawing process, according to exemplaryteachings of the present disclosure;

FIG. 11 depicts a simplified diagram with relevant elements of analternative exemplary surface-adhesive-rule technology (SART) system inaccordance with some exemplary embodiments of the present disclosure;

FIG. 12 depicts a schematic illustration of relevant elements of yetanother exemplary surface-adhesive-rule technology (SART) systemdepositing pieces of material in accordance with some exemplaryembodiments of the disclosure;

FIG. 13 depicts a schematic illustration of relevant elements of anexemplary SAR die (SARD) produced with the SART system shown in FIG. 12,according to exemplary teaching of the present disclosure;

FIGS. 14 a-c are schematic illustrations of SAR dies (SARDs) produced inaccordance with yet other embodiments of the present disclosure;

FIG. 15 depicts a schematic illustration of relevant elements of anotherexemplary surface-adhesive-rule technology (SART) system, according toexemplary teaching of the present disclosure;

FIG. 16 a-b depicts schematic illustration of relevant elements of aportion of an exemplary embodiment of a molding system for creating aSARCD and/or SARD body, according to exemplary teaching of the presentdisclosure;

FIG. 17 a-b depicts schematic illustration of relevant elements of aportion of an exemplary embodiment of a press system for creating aSARCD and/or SARD body, according to exemplary teaching of the presentdisclosure;

FIG. 17 c depicts schematic illustration of relevant elements of aportion of an exemplary embodiment of a inject/extruder system forcreating a SARCD and/or SARD body, according to exemplary teaching ofthe present disclosure;

FIG. 18 depicts schematic illustration of relevant elements of a portionof an exemplary embodiment of a coating system for creating a SARCDand/or SARD body, according to exemplary teaching of the presentdisclosure; and

FIG. 19 depicts schematic illustration of relevant elements of a portionof an exemplary embodiment of a SART controller, according to exemplaryteaching of the present disclosure.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Turning now to the figures in which like numerals and/or labelsrepresent like elements throughout the several views, exemplaryembodiments of the present disclosure are described. For convenience,only some elements of the same group may be labeled with numerals. Thepurpose of the drawings is to describe exemplary embodiments and is notfor production purpose. Therefore features shown in the figures are forillustration purposes only and are not necessarily drawn to-scale andwere chosen only for convenience and clarity of presentation.

FIG. 1 a depicts a block diagram with relevant elements of an exemplarycommon prior art steel-rule die 100. Steel-rule die 100 may comprise abody 110, and a plurality of steel-rules: steel-rule 112 and steel-rule114, for example. Steel-rules 112 and 114 may be cutting rules, creasingrules, embossing rules, etc. The body 110 may be made of hard-woodmaterial, for example.

FIG. 1 b depicts cross-sectional view of the exemplary prior artsteel-rule die 100 of FIG. 1 a taken at line A-A. Steel-rule 112 may bejammed deeply inside the body 110 of the steel-rule die, even extendingto the point that is all the way through the body 110. Steel-rule 114may be jammed inside part of the steel-rule die's body 110.

FIG. 2 a schematically illustrates a simplified portion of a blockdiagram with relevant elements of an exemplary surface-adhesive-rule die200 (SARD). The surface-adhesive-rule die 200 (SARD) may comprise a body210, and a plurality of surface-adhesive rules (SAR): SAR 212 and SAR214, for example. Surface-adhesive rules (SAR) 212 and 214 may be ofdifferent types. Exemplary SAR types may be: cutting SAR; creasing SAR;embossing SAR; etc. Henceforth, throughout the description, drawings andclaims of the present disclosure the terms cutting SAR, creasing SAR,embossing SAR, etc. may be used interchangeably and the term SAR used byitself may refer to any of these types.

SAR 212 and SAR 214 may be made of flexible material, for example. Theflexible material may be gel or liquid like material. The flexiblematerial may include one or more different types of polymers and/ordifferent combinations of polymers. Exemplary polymers that may be usedinclude, but are not limited to: polyester, polyamide, polycarbonate,polyurethane, acrylic, polypropylene, polyethylene, etc. Furthermore,the flexible material may include one or more additives. The additivesmay include, but are not limited to: silica, ceramics, metal, variousfibers, different fillers, etc. Exemplary embodiments SAR may compriseseveral layers (co layer), and each such layer be constructed from adifferent material or, one or more layers may be constructed fromdifferent material.

The exemplary SAR 212 and SAR 214 may have a strong enoughsustainability, firmness, inside-cohesion, robustness, and/or lifespanto withstand the pressure and harsh operation of high pressure pressforce in one or more directions on the SAR during thecutting/creasing/embossing operation of numerous cardboards. Thepressure press force may be around a few tons. 1-10 ton pressure pressforce, for example.

The flexible material may have additional attributes as well. Exemplaryattributes may include, but are not limited to: flexibility, tackiness,spreading capabilities, required thickness, etc. Different ingredientsin the flexible material, and the ratio between these ingredientsinfluence the presence and/or ranges of the different attributes.Exemplary ingredients may include, but are not limited to: differentpolymers, silica, ceramics, fillers, fiber etc. Exemplary ratios in thecombinations of different polymers, silica, ceramics, fillers areillustrated in the following tables:

TABLE 1 Ingredient % Weight Exemplary supplier SPF 918 81.4 RAHN AEROSILR-972 13.0 EVONIK Genocure LTM 2.8 RAHN Genocure LBC 2.8 RAHN

TABLE 2 Ingredient % Weight Exemplary supplier SPF 918 80.9 RAHN AEROSILR-812 13.5 EVONIK Genocure LTM 2.8 RAHN Genocure LBC 2.8 RAHN

TABLE 3 Ingredient Weight Exemplary Supplier U-1050 100 Polymer GvulotEPC-238 34-45 Polymer Gvulot AEROSIL R-972 100 EVONIK

TABLE 4 Ingredient Weight Exemplary Supplier U-233 100 Polymer GvulotEPC238 34-45 Polymer Gvulot CabOsil M5  24 CABOT

TABLE 5 Ingredient Weight Exemplary Supplier U-233 100 Polymer GvulotEPC238 34-45 Polymer Gvulot Aerosil R-812  24 EVONIK

In some embodiments the flexible material of the SAR may be:thermoplastic polymers, thermosetting polymers, metal, a combination ofthem, and so on. Exemplary flexible material may comprise: Polyurethane,having a hardness of 60-99 shore A, preferably, 80-99 shore A orPolypropylene, etc. Optionally, the viscosity of the material asdeposited (drawn) may be between 1,000 cps and 145,000 cps, preferablybetween 17,000 cps and 80,000 cps, etc.

Yet in some embodiments, the SAR may be a cutting SAR. According tothese embodiments, the edges of the SAR may be milled in order to form asharpened edge adapted for cutting, for example. The milling may be doneby mechanical or optical equipment. In these embodiments, the SARs maybe have a hardness of 85 shore A and more or 35 shore D and more.Exemplary materials that may be used are: polymers loaded with glassfiber, carbon fiber, Kevlar fiber or fillers like silica, metal, carbonblack etc.

The exemplary body 210 of the surface-adhesive-rule die (SARD) 200 210may be made of or comprise a flexible film. The flexible film mayinclude one or more types of polymers. Exemplary polymers that may beused include, but are not limited to: polyester, polyamide,polycarbonate, and/or a combination of one or more of these polymers aswell as other polymers and non-polymers. Furthermore the flexible filmmay include one or more additives. The additives included in theflexible film may include, but are not limited to: silica, ceramics,metal, different fillers, etc. Exemplary embodiments of the flexiblefilm may have one or more layers and, each layer may utilize or containa different material than one or more of the other layers. In someexemplary embodiments, the flexible film may be a commercial one.

Exemplary flexible films that may be used in the body 210 of asurface-adhesive-rule die 200 (SARD) may include, but are not limitedto: PET (Polyethylene terephthalate), PA (Polyamide), polypropilen,stainless steel, Aluminum (Al) and/or a combination of one or more ofthese materials as well as others. Exemplary suppliers for suchmaterials are: HANITA Company (an Israeli company), SKC Company, ALCAMVAW Company, etc. Some exemplary embodiments of the body 210 of thesurface-adhesive-rule die 200 (SARD) may be comprised of a combinationof two or more flexible films. Exemplary combinations may include, butare not limited to: 23 micron thickness of PET associated to 25 micronthickness of Al; and/or 25 micron thickness of PET associated to 25micron thickness of Al; and/or 36 micron thickness of PET associated to45 micron thickness of PA; and/or 23 micron thickness of PET associatedto 15 micron thickness of PA and 18 micron thickness of Al; etc.

The body 210 of the SARD may be associated with, adhered to or otherwisecombined with a substrate made of material other then flexible film.These other materials may include, but not limited to: metal, wood,plastic, etc. Furthermore, the body 210 of the SARD may have a flat,cylindrical or other shape. In addition, the body 210 of the SARD may beflexible such that it's shape can be n changed, for example from flat tocylindrical to be wrapped around a drum, for example.

The body 210 of the SARD may have a strong enough sustainability,firmness, inside-cohesion, robustness, and/or lifespan to withstand thepressure and harsh operation which can be around a few tons of pressforce (1-10 ton, for example) in one or more directions during thecutting/creasing/embossing operation of the cardboards. In otherexemplary embodiments, the body 210 of the SARD may be made of materialother then flexible film, and/or a combination of various materials.

The flexible film may have additional attributes such as being flexible,tacky, spreadable, meeting required thicknesses, etc. Differentingredients in the flexible film, and the ratio between theseingredients influence the ratio or the characteristics of the differentattributes. Exemplary ingredients may include, but are not limited to:different polymers, silica, ceramics, fillers, fiber etc.

FIG. 2 b depicts a cross-sectional view of the exemplarysurface-adhesive-rule die 200 (SARD) taken at line A-A. Exemplary SAR212 and SAR 214 may be bonded to the surface of the body 210 of the SARDby adhesion. Exemplary adhesion techniques may include using anintermediated-adhesive material between the SAR (212 and/or 214) and thesurface of the body 210 of the SARD. Intermediated adhesive materialsmay include, but are not limited to: adcote 811 of DOW company,238A+catalyst of MORCHEM company, etc. Other exemplary embodiments ofadhesion may be achieved by adhesive attributes of the SARs 212 and 214materials and the materials used in the body 210 of the SARD. Adhesiveattributes may include, but are not limited to: epoxy, oligomer,silicone acrylate oligomer, adhesion promoter, photoinitiator. In someembodiments, the bonding may be done by hardening, such as thermalcuring, chemical curing, UV curing, etc. Yet in other exemplaryembodiments a combination of the two or more techniques may beimplemented and other techniques are also anticipated.

FIG. 3 a schematically illustrates a simplified diagram with relevantelements of an exemplary surface-adhesive-rule die (SARD) 300 a. TheSARD 300 a may comprise a body 310 and a surface-adhesive rule (SAR)312. The SAR 312 may be adhered to the surface of the body 310. FIG. 3 bschematically illustrates a simplified diagram with relevant elements ofan exemplary surface-adhesive-rule die (SARD) 300 b, in which the shapeof a surface-adhesive rule (SAR) 314 may comprise a wide base 318, and arounded-shape top edge 316.

The wide base 318 may improve the bonding of the SAR 314 to the body 310of the SARD 300 b. The wide base 318 may further enhance the ability ofSAR 314 to withstand the numerous forces that may be applied duringcutting/creasing/embossing operations. The shape of the top edge of theSAR 314 may match the functionality of the SAR 314. For example, therounded-shape edge 316 may be used for creating crease lines on thesurface of a cardboard.

FIG. 3 c illustrates another exemplary embodiment of a SARD 300 c. Theillustrated SARD 300 c may comprise a SAR 320 with a sharp top edge 322.The shape of the top edge of the SAR 320 may match the functionality ofthe SAR 320. For example, the sharp edge 322 may be used for creatingcutting lines on the surface of a cardboard. The SAR 320 may furthercomprise shoulder-like sides 324. The shoulder-like sides 324 enhancethe ability of the SAR 320 to withstand the numerous forces duringcutting/creasing/embossing operations. In some exemplary embodiments thesharp edge may be achieved by further milling (scraping) the edge afterhardening the SAR.

FIG. 3 d schematically illustrates yet another simplified diagram withrelevant elements of an exemplary SARD 300 d. The SARD 300 d maycomprise a co-layer SAR 326. The co-layer SAR 326 may be comprised of 3different types of layers, for example. One type of a layer for the base330, another type of a layer for the shoulder-like sides 328, and athird type of a layer for the rest of the body of the SAR 329 and itstop edge.

Each of the co-layers in the illustrated SAR 326 may be made ofdifferent materials or, one or more co-layers may be different from theother co-layers. Each co-layer may have a different: shape;cross-section; width; comprise different polymer types and/or additives;etc. Each co-layer may also have a different required attributes. Forexample, the lower base layer 330 may be required to have betteradhesive attributes, the highest layer 329 may be required to have moreelastic attributes, the shoulder-like sides may be required to have morefirmness attributes 328, and so on. Other exemplary embodiments ofco-layered SARs may have a different number of co-layers and differentconfigurations of shapes and attributes.

FIG. 3 e illustrates yet another exemplary embodiment of a SARD 300 e.The illustrated SARD 300 e may comprise a SAR 332 with an asymmetricalshape. SAR 332 may be comprised of a one shoulder-like side 334 and anasymmetrical base 336, for example. An asymmetrical SAR may be used whendrawing adjacent SARs. FIG. 3 f illustrates an exemplary embodiment of aSARD 300 f. The SARD 300 f may be comprised of a SAR 338 with atrapezoid-like shape top edge 340. The trapezoid-like shape top edge 340may be used as a cutting SAR in a rotary system, for example. It shouldbe appreciated that in other exemplary embodiments, differentcombinations of two or more different profile SARs, and/or profile typesother then the SARs depicted in FIG. 3 a-3 f may be used.

FIG. 4 depicts a schematic diagram with relevant elements of a portionof an exemplary surface-adhesive-rule technology (SART) utilizing arotary system 400. The surface-adhesive-rule technology's (SART) rotarysystem 400 may be used for drawing a plurality of surface-adhesive rules(SAR) 460-463 on the surface of a surface-adhesive-rule die's (SARD)body 420. The SARs 460-463 may protrude from the surface of the SARD'sbody 420 and may have different shapes and sizes. The SARs 460-463 maybe functional and configured for cutting, creasing, embossing, etc.and/or a combination of two or more of these functions.

Surface-adhesive-rule technology's (SART) rotary system 400 may includea drum 410 on which the SARD's body 420 may be positioned. The body 420of the SARD may be associated with or joined to the drum 410 using avariety of techniques including, but not limited to: adhesion, gripers,molding, coating, etc. In exemplary embodiments, the body 420 of theSARD may be removed from the drum 410 after the SARs 460-463 arecreated. In other exemplary embodiments, the body 420 of the SARD may beleft on the drum 410, to be used for cutting/creasing/embossingcardboards operations in a rotary system, for example. In some exemplaryembodiments, SART's rotary system 400 may include one or more drums.

A similar SART's rotary system 400 may be used for producing aSAR-counter die (SARCD). The SAR-counter die (SARCD) may be associatedwith the drum 410 in a similar ways as described elsewhere herein withregards to the body 420 of the SARD. In an exemplary embodiment, theSART's rotary system 400 may produce one flexible film layer to act as aSAR-counter die (SARCD). In alternate embodiments, the SART's rotarysystem 400 may produce a plurality of different flexible film layers toact as a SARCD. In yet another exemplary embodiment, the SART's rotarysystem 400 may produce only portions of the surface of the SAR-counterdie's body, and so on. Other exemplary embodiments of producing aSAR-counter die (SARCD) are disclosed in conjunction with thedescription of FIGS. 16, 17 and 18 for example.

Exemplary SART's rotary system 400 may roughen the surface of theSARCD's body and/or the surface of the body 420 of the SARD usingdifferent tools. These tools may include, but are not limited to: ascraper, a laser, etc. Further, the SART's rotary system 400 may engravea desired layout of trenches with a laser or mechanical tool, forexample. In alternate exemplary embodiments, the SARCD body's surfacemay not cover the entire surface of the die's body. For example, it maybe just two raised areas. The two raised areas may be drawn, molded,coated, etc.

In exemplary embodiments of the present disclosure, the SARCD's bodyand/or the SARD's body 420 may be made of flexible film. The flexiblefilm may include one or more types of polymers. Exemplary polymers thatmay be used include, but are not limited to: polyester, polyamide,polycarbonate, and a combination of these or other polymers or polymerlike substances. Furthermore, the flexible film may include one or moreadditives. These additives may include, but are not limited to: silica,ceramics, metal, different fillers, etc. Exemplary embodiments of theflexible film may comprise several layers. Each layer may comprisedifferent materials.

The flexible film of the SARCD's body may have a strong enoughsustainability, firmness, inside-cohesion, robustness, and lifespan towithstand the pressure and harsh operation which can be around a fewtons of press force in one or more directions during thecutting/creasing/embossing operation of the cardboards. The SARCD's bodymay be associated with a substrate made of other material. Thesematerials may include, but are not limited to metal, wood, plastic, etc.

The SAR 460-463 on the body 420 of the SARD may be flexible enough tobend even after hardening, but still rigid enough to serve theirpurposes of cutting, creasing and/or embossing.

SART's rotary system 400 may further include one or more rule-drawers.Exemplary embodiments of the rule-drawer may comprise: a drawing head435, a controller 470, and one or more rails 430. The drawing head 435may comprise: at least one nozzle 440, at least one cartridge 445fluidly associated with the nozzle 440. The nozzle 440 may be associatedwith the rail 430. In exemplary embodiments, the nozzle 440 may slideupon the rail 430. In exemplary embodiments, the cartridge 445 isassociated with the rail 430 as well. In other exemplary embodiments thecartridge 445 may be independent from the rail 430. Cartridge 445 maycomprise flexible material that will be output by nozzle 440, thusdrawing SARs 460-463, for example.

In exemplary embodiments, the cartridge 445 and the nozzle 440 may beassociated with or controlled by a motor for moving the cartridge 445and/or nozzle 440 back and forth on rail 430 in a direction indicated byarrow 450. In addition, the nozzle 440 may be adapted to rotate in thedirections indicated by arrows 452. Optionally, nozzle 440 may also moveup and down in the directions indicated by arrows 454. It should benoted, in some embodiments, the drawing-head 435 may be used as a singleunit, while in other embodiments the nozzle 440 and/or the cartridge 445may be moved independent from each other.

Drum 410 may be adapted to rotate in a counter-clockwise directionindicated by arrow 455. Optionally, drum 410 may rotate in a directionopposite to the direction indicated by arrow 455 (i.e., clockwise), andyet in some exemplary embodiments, the drum 410 may rotate in bothdirections. Further, the drum 410 may also be configured to movelaterally in relationship to the rail. The controller 470 may operate tocontrol and coordinate the movement and operations of the differentmodules or elements, as well as the operations of the SART's rotarysystem 400. For instance, the controller 470 may operate to control therotation of the drum 410, the movement of the nozzle 440 and thecartridge 445; etc. The controller 470 may also instruct and control thenozzle 440 and cartridge 445 to deposit flexible material on SAR die'sbody 420 in order to draw a desired layout of SAR 460-463.

The nozzle 440 may output flexible material while moving in differentdirections. Exemplary directions may include, but are not limited to:directions indicated by arrows 450, 452 and/or 454 on rail 430 whiledrum 410 may move in the direction 455 and/or opposite to 455 as well asother directions. For example, in order to output, and thus draw SAR461, drum 410 may move in a direction 455 (or opposite to thisdirection) while the nozzle 440 may remain in place. After acircumferential line SAR 461 may be completed, the nozzle 440 may bemoved in direction 450 to draw SAR 462 while the drum 410 may remainsstationary. Likewise, the SAR 462 can be drawn by moving the drum 410 inthe direction of arrow 450 while the nozzle 440 remains stationary.Furthermore, SAR 462 can be drawn by moving the drum 410 in onedirection along the path of arrow 450 and moving the nozzle 440 in anopposite direction.

In an exemplary embodiment, the SARs 460-463 may be drawn in onecontinuous deposit of flexible material by nozzle 440. Alternatively,the SARs 460-463 may be drawn by depositing a plurality of layers, eachlayer may comprise different flexible materials.

During the production of a single SARD 420 or SARCD, the drum 410 mayrotate several times on its axis while the nozzle 440 may move a singletime on rail 430. In other embodiments, the drum 410 may rotate a singletime around its axis while nozzle 440 moves several times in differentdirections. Optionally, the nozzle 440 may be moved along rail 430 atthe same time as drum 410 rotates to draw a diagonal and/or curved SAR.The speed and/or direction of rotation and/or movement of the nozzle 440may depend on: the type and form of flexible material output, and thesection of the SAR 460-463 being drawn, the layout, etc. The speedand/or direction of rotation and the movement of the nozzle 440 may becontrolled by controller 470, for example.

The flexible material deposited by the nozzle 440 may include one ormore different types of polymers or different combinations of two ormore polymers or material having similar characteristics. Exemplarypolymers that may be used are: polyester, polyamide, polycarbonate,polyurethane, acrylic, polypropylene, polyethylene, etc. Furthermore,the flexible-material may include one or more additives. The additivesmay include, but are not limited to: silica, ceramics, metal, variousfibers, different fillers, etc.

In exemplary embodiments, the flexible material of the SARs may compriseseveral layers (co-layers). Each layer may be made of differentmaterials and/or each layer may have a different: shape; cross-section;width; comprise different polymer types and/or additives; etc. Eachlayer may also have a different required set of attributes. Moreinformation on layers of the SAR is presented herein in conjunction withthe description of FIG. 3 d and FIGS. 9 a-b.

The flexible material output by the nozzle 440 may be hardened afterand/or while the drawing is being performed. The hardening may beaccomplished by a hardener 480. The hardener 480 may irradiate energythat can cause the drawn flexible material to harden and/or adhere.Irradiated energy may include, but is not limited to: ultra violet (UV)light, visible light, heat, etc. Alternatively, cooler air may bedirected at the drawn flexible material to cool and thus harden thematerial.

The type of energy irradiated by the hardener 480 generally depends onthe type of flexible material and the hardening characteristics of thatmaterial. For example, when the flexible material is a thermosettingmaterial, heat may be applied by the hardener 480. When the flexiblematerial is a thermoplastic material, the hardener 480 may cool thematerial in order to harden it. Yet when the flexible material iscomprised of photo-initiator ingredients, the hardener 480 mayilluminate UV lighting in order to harden the flexible material.Optionally, when one or more flexible materials utilized, one or moretypes of hardeners 480 may be used.

The hardener 480 may be positioned adjacent to the nozzle 440 such thatthe flexible material may be hardened immediately after it is drawn. Inother exemplary embodiments the hardener 480 may be positioned at adistance from the nozzle 440. In some embodiments, the hardener 480 maynot be provided in SART's rotary system 400 and SAR 460-463 may behardened by another system. In yet other exemplary embodiments, nohardener 480 may be used.

In some exemplary embodiments, the hardener 480 may be used forpre-treatment. The pre-treatments may include, but are not limited to:ozone showers, primer coatings, surface roughening, etc. In embodimentsin which the hardener 480 is used for pre-treatment, the hardener 480may comprise different modules (not shown in drawings). Exemplarymodules include but are not limited to: laser beams, UV flash light,cartridge(s) with primer substances, cartridge(s) with adhesivesubstances, and so on. The hardener 480 and its modules may becontrolled by the controller 470, for example.

FIG. 5 illustrates an exemplary portion with relevant elements of asurface-adhesive-rule technology's (SART) flat system 500. The SART'sflat system 500 may be used for drawing an exemplary SAR 560 on thesurface of a SARD's body 520 that may be positioned on a flat substrate510. The SART's flat system 500 may include one or more rule-drawers.Exemplary embodiments of the rule-drawer may comprise: a drawing-head535, a controller 570, and one or more rails 530. The drawing-head 535may comprise: at least one nozzle 540 and at least one cartridge 545associated with or fluidly coupled to the nozzle 540.

The SAR 560 may be drawn by the at least one nozzle 540 associated withthe at least one cartridge 545. The nozzle 540 may further be associatedwith a motor to cause the nozzle 540 to traverse along the rail 530 inthe directions of arrow 550, for example. Optionally, the nozzle 540 mayalso be adapted to rotate in directions illustrated by arrows 552 and/or554. The rail 530 may be situated between two rails 535, substantiallyperpendicular to rail 530 and is adapted to travel in the directions ofarrow 555, for example.

Control 570 may be adapted to control the movement and coordinate thedifferent modules of the SART's flat system 500. For example thecontroller 570 may control one or more of the nozzle 540, the rail 530,the cartridge 545, etc. In some exemplary embodiments, the SART's flatsystem 500 may further include a hardener 580 for hardening and/oradhering the SAR 560 to the surface of the SARD's 520 body, similar tohardener 480 shown and described in conjunction with the description ofFIG. 4. In some embodiments, flat substrate 510 may be adapted to movein the directions depicted by arrow 555. It will be appreciated thatvarious other configurations may be used in various embodiments and aslong as the configurations allow the nozzle 540 and the body 520 of theSARD to be moved relative to each other sufficiently to cover therequired area of the body 520 of the SARD, and to deterministically drawthe SARs, then the configuration is anticipated. In some embodiments,the SARD's body 520 may be bent around a cylindrical drum, after thedeposition of the SARs. The SART's flat system 500 and SART's rotarysystem 400 may be similar in their functionality.

FIG. 6 depicts relevant elements of an exemplary embodiment of adrawing-head 600. The drawing-head 600 may be comprised of a nozzle 640for depositing flexible material. The nozzle 640 may be associated withor fluidly coupled to a cartridge 645. The cartridge 645 may containflexible material and associated with a pressure actuator (not shown inthe drawing) for depositing the flexible material by injecting it orforcing it through the nozzle 640 to draw a desired SAR. In someembodiments, the nozzle 640 and its orifice may have various shapes.More information on the different shapes and orifices is disclosed inconjunction with the description of FIGS. 7 a-b.

FIG. 7 a is a schematic illustration of relevant elements of anexemplary nozzle 700 a. The exemplary embodiment of the nozzle 700 a mayinclude a first tube 742 that may be substantially perpendicular to thebody 740 of the SARD. A second tube 744 may be oriented substantiallyperpendicular to the first tube 742 and parallel to the body 740 of theSARD. The tube 744 may have an orifice 746 at its end through whichflexible material may be output toward the body 740 of the SARD. Theorifice 746 may have different cross-sectional shapes. Thecross-sectional shapes of the orifice may be determined according to therequired SAR profile, for example. Exemplary cross-sectional shapes ofthe orifice 746 may match the profile of the SARs depicted in FIG. 3a-f, for example.

FIG. 7 b is a schematic illustration of relevant elements of anotherexemplary nozzle 700 b. The exemplary embodiment of the nozzle 700 b mayinclude a tube 752 that is oriented substantially perpendicular to aSARD's body 750. The tube 752 may include an orifice 756 through whichflexible material may be output toward the body 750 of the SARD. Theorifice 756 may have various shapes as described in conjunction withorifice 746 of FIG. 7 a. Optionally, the tube 752 may be closed at itsdistal end 758, and the material may be released substantially parallelto SARD's body 750, through opening 756. Alternatively, distal end 758may be open and the flexible material may be output in a substantiallyperpendicular manner through distal end 758 as well as through 756, andso on. Wherein substantially perpendicular may be in the range of 90degree plus/minus 30 degrees, for example.

Other nozzles may be used in accordance with embodiments of the presentdisclosure. For example, nozzles manufactured by Nordson Corporationwhich can be viewed at the following URL www<dot>nordson<dot>com may beutilized. The types of nozzles used may differ according to: thematerial that is being output onto the SARD, the required shape of SAR,etc. In some exemplary embodiments, the orifice of the nozzle may bedirected in a direction opposite to the relative direction of motion ofthe nozzle with respect to the surface of the SARD's body 750. Inexemplary embodiments the orifice of the nozzle may be parallel to thesurface of the SARD's body 750. In alternate embodiments the nozzle maybe at a pre-defined angle to the surface of the SARD's 750. Exemplaryangles may be at the range of 45-135 degree.

FIG. 8 a schematically illustrates a simplified diagram with relevantelements of an exemplary pressure actuator 800 a. The pressure actuator800 a may be an air-pump actuator, for example. A cartridge 810 maycontain a flexible material 814, for example. The flexible material 814may be used to draw SARs for example. The cartridge 810 may have anoutput 816 through which the flexible material 814 may be output or usedto fluidly couple the cartridge 810 to a nozzle. The cartridge may havean input 812 through which air may be compressed and thus press thematerial out of the cartridge's output 816 via a nozzle (not shown indrawing) according to a SAR layout. The air may be compressed by apiston 808, for example. The piston 808 may be controlled by acontroller similar to the controller 470 of SART rotary system 400and/or controller 570 of SART flat system 500. Pressure actuators 800 amay have suction capabilities as well.

FIG. 8 b schematically illustrates a simplified diagram with relevantelements of exemplary pressure actuators 800 b. The pressure actuator800 b may an electrical cogwheel pump, for example. The cartridge 810and flexible material 814, may be similar to that as described for thecartridge 810 and flexible material 814 in FIG. 8 a. The flexiblematerial 814 may be carried by a cogwheel 822 out of the cartridgeoutput 816. The cogwheel 822 may be actuated by an electric/step motor818, for example. The operation of the cogwheel 822 and the motor 818may be controlled by a controller similar to controller 470 of SARTrotary system 400 and/or controller 570 of SART flat system 500. Theflexible material may be output from the cogwheel's 822 output 820 to anozzle (not shown in the drawing) according to a SAR layout. Pressureactuator 800 b may have suction capabilities as well.

FIG. 8 c schematically illustrates a simplified diagram with relevantelements of an exemplary pressure actuator 800 c. The pressure actuator800 c may be a screw-piston pump, for example. The screw-piston pump maybe comprised of a screw 822 associated with a plate 824, and an engineor motor 823, for example. Cartridge 810 and flexible material 814, maybe similar to the cartridge 810 and flexible material 814 described inFIG. 8 a. The flexible material 814 may be pressed out of the cartridgeoutput 816 by the screw-piston pump as the screw 822 is screwed by theengine 823, thus causing the plate 824 to press the flexible material814 out of the cartridge 810 output towards a nozzle (not shown indrawing) according to a SAR layout. The operation of the screw-pistonpump 800 c may be controlled by a controller similar to controller 470of SART rotary system 400 and/or controller 570 of SART flat system 500.The screw-piston pump 800 c may have suction capabilities as well.

FIG. 8 d schematically illustrates a simplified diagram with relevantelements of an exemplary pressure actuator 800 d. The pressure actuator800 d may be a screw pump 832, for example. The cartridge 810 andflexible material 814, may be similar to the cartridge 810 and flexiblematerial 814 described for FIG. 8 a. The flexible material 814 may becarried out between the spindles of the screw 832 toward the cartridgeoutput 816 and towards a nozzle (not shown in drawing) according to aSAR layout by the screw pump 832 as the screw pump 832 is screwed by anengine 833. The operation of the screw pump 832 may be controlled by acontroller similar to controller 470 of SART rotary system 400 and/orcontroller 570 of SART flat system 500. The screw pump 832 may havesuction capabilities as well.

FIG. 8 e schematically illustrates a simplified diagram with relevantelements of an exemplary pressure actuator 800 e. The pressure actuator800 e may be a screw pump 832, for example. The pressure actuator 800 emay be similar to the pressure actuator 800 d described in conjunctionwith FIG. 8 d. The pressure actuator 800 e may further comprise acut-off mechanism. The cut-off mechanism may comprise a tube 842 inwhich pulses of air, liquid, etc. may pass through in the direction ofarrow 844, for example. The air, liquid, etc. pulses may be created by apulse-pump 843 associated with the tube 842, for example.

The cut-off mechanism may further comprise a switch/valve that may becontrolled by a controller similar to controller 470 of SART rotarysystem 400 and/or controller 570 of SART flat system 500. The pulse-pump843 may be controlled by the controller, as well. The switch/valve maycomprise a shutter arm 846 or may be a ball valve or other structure.The switch/valve may have two modes. One mode may be an open-mode inwhich the shutter arm 846 is substantially parallel to tube 842. Thesecond mode may be a closed-mode in which the shutter arm 846 issubstantially perpendicular to tube 842 or oriented in a manner toprevent flow.

In an exemplary embodiment, when the cut-off mechanism is activated, atthe end of a SAR drawing for example, the following actions may takeplace: output of the flexible material by screw-pump 832 is stopped; thescrew-pump 832 may be screwed in the counter-clockwise direction (orretracted); the shutter arm 846 is switched to open-mode in thedirection similar to arrow 848; a pulse of air, liquid, etc. may becreated and output from the pulse-pump 843 in direction of arrow 844. Inother exemplary embodiments one or more shutter arms or valves may beused.

FIG. 8 f schematically illustrates a simplified diagram with relevantelements of an exemplary pressure actuator 800 f. The pressure actuator800 f may be similar to pressure actuators 800 a-e described inconjunction with FIGS. 800 a-e. The pressure actuators 800 f may furthercomprise a filling mechanism. The filling mechanism may comprise areservoir 856 that may contain flexible-material 814; a tube 858 inwhich the flexible material may pass through; and a switch/valve thatmay be controlled by a controller similar to controller 470 of SARTrotary system 400 and/or controller 570 of SART flat system 500.

The switch/valve may comprise a shutter arm 854. The switch may have twomodes. One mode may be open-mode in which the shutter arm 854 issubstantially parallel to tube 858 and may shut aperture 860. The secondmode may be closed-mode in which the shutter arm 854 is substantiallyperpendicular to tube 858 or oriented such that the flow from tube 858is restricted.

In an exemplary embodiment, when the filling mechanism is activated, andthe cartridge 810 is required to be filled with flexible material 814for example, the following actions may take place: output of theflexible material from output 816 is stopped; piston 808 may be pulledoutward from cartridge 810; the shutter arm 854 may be switched toopen-mode in the direction similar to arrow 852; flexible material maybe output from the cartridge 856 toward the shutter arm 846. In otherexemplary embodiments one or more shutter arms may be used. In otherembodiments the cartridge 810 may be filled through opening 812, forexample. The cartridge 856 may be easily and quickly disconnected fromtube 858, and replaced with another one, for example. The Cartridge 856and it's flexible material may be purchased by the owner of the SARTsystem.

FIG. 9 a depicts a simplified diagram with relevant elements of anexemplary embodiment of a multiple-compartment cartridge 900. Themultiple-compartment cartridge 900 may be used to draw a co-layer SAR,for example. The multiple-compartments cartridge 900 may comprise aplurality of compartments 902, 904, and 906 for example. Eachcompartment may comprise a cartridge and a pressure actuator (not shownin the drawings), for example. Each compartment 902, 904, and 906 maycontain, separately, one or more ingredients of flexible material. Inalternate embodiments each compartment may comprise a different flexiblematerial, for a different layer of the co-layer, and so on.

The cartridge 900 may further comprise a combiner 908. In exemplaryembodiments, the combiner 908 may combine the different ingredientsand/or flexible material, for example. The combiner 908 may comprise aslot/aperture 910 through which the combined material from the differentcompartment 902, 904, and 906 may be output. A controller, 470 (FIG. 4)and/or controller 570 (FIG. 5), may control the quantities of eachingredient/material/layer. In some exemplary embodiment one or more ofthe different compartments 902, 904, and 906 may comprise adhesivesubstance. In addition, the combiner 908 may include an agitator (notshown) to facilitate the mixing and combining of the materials from twoor more of the different compartments 902, 904, and 906.

The different layers may be bonded to one another during differenthardening techniques, for example. Exemplary hardening techniquesinclude, but are not limited to: temperature treatment, Ultra-Violet(UV) curing, visible light, infra red light, chemical curing, coolingetc. In other embodiments, the different layers may be bonded by anadhesive. In such embodiments, an adhesive substrate layer compartmentmay be placed between the compartments comprising the layers that willneed to be adhered. In yet other embodiments the bonding may be acombination of the above techniques.

FIG. 9 b schematically illustrates a co-layer creation by an exemplaryembodiment of a multiple-compartment cartridge 910. Themultiple-compartment cartridge 910 may comprise a plurality ofcompartments 912, 914, and 916 for example. The compartment 916 may bethe leading edge of the drawing head 910. Each compartment may comprisea cartridge and a pressure actuator (not shown in the drawing). In anexemplary embodiment, each compartment may comprise a different flexiblematerial, for a different layer of the co-layer, and so on. Acontroller, 470 (FIG. 4) and/or controller 570 (FIG. 5), may control theco-layer drawing, for example. In some exemplary embodiments, one ormore of the different compartments 912, 914, and 916 may compriseadhesive substance. The multiple-compartments cartridge 910 may have astair-like shape edge.

In some embodiments, the co-layer may be created in phases. An exemplaryphase technique includes, but is not limited to: drawing a first layeron the surface, next drawing on top of it the next layer and so on. Thisexemplary embodiment may comprise a plurality of cartridges. Eachcartridge may comprise a different material for a different layer and/oradhesive substance. The controller may control the operation. In someembodiments, a combination of the different co-layer techniques andmultiple-compartments cartridge may be used.

FIG. 10 a-d schematically illustrates a flowchart showing relevantprocesses or actions of an exemplary rule drawing method 1000. Theillustrated rule drawing method 1000 may be executed by a controller, amicroprocessor, a microcontroller, a computer or any other processingdevice including (collectively referred to as a controller), but notlimited to controllers similar to controller 470 (FIG. 4) and/orcontroller 570 (FIG. 5). The method 1000 may be initiated 1002 uponpowering on the controller but, it will be appreciated that the method1000 may be initiated or invoked from other processes, system, events,user actions, etc. During initiation 1002, the controller may operate todetect the various modules in the system or, the various modules orother processors may provide information to the controller to identifythe different modules. Exemplary modules may include, but are notlimited to: drawing head modules, different registers, different timers,etc. After being invoked the process may then act to reset, initializeor determine the state of various resources, registers, variables,memory components, etc. 1004. The various resources may include, but arenot limited to: timers (t), counters (R), distance measurers (D), and soon.

After the system resources have been initialized 1004, the rule drawingmethod 1000 may enter into a delay loop waiting for the reception of aninitiation command 1006. The initiation command directs the rule drawingmethod 1000 to commence the creation of a SARD. When an initiationrequest is received 1006, the method 1000 may proceed to act 1008 byreceiving or obtaining the entry of various inputs or parameters used inthe creation of SARD. The inputs may be received, obtained or entered bya user, provided by a processor or other entity, read from an electronicfile, etc. Exemplary inputs may include, but are not limited to: thedepth or thickness of the cardboard that will be pre-treated while usingthe SARD, the type of surface-adhesive rules (SAR) that will berequired, the requested layout, and so on. The method 1000 may check1010 a look-up table for information on the required job description.Exemplary information may include, but is not limited to: the definitionof flow index for each SAR, the definition of profile for each SAR, thedefinition of the layers for the co-layers, the type of SAR(cutting/embossing/creasing), etc.

Once the information has been received, the method then decides whetheradditional information in the look-up table has been found or isavailable 1012. If additional information is not found 1012, then method1000 may prompt the user or other information provider to enter orprovide the information 1014, and processing then returns to act 1008 tocheck for this information. If the method obtains the information in thelook-up table or otherwise 1012, then the method 1000 may proceed to act1018. The method 1000 may then proceed to execute a SAR drawing loopthat comprises the acts listed in blocks 1018 through 1046 (FIG. 10 d).The first action in the SAR drawing loop comprises increasing counter Rby one (incrementing R) 1018, and the method 1000 may begin drawing aSAR in accordance with the information received at action 1010 andlayout requirements, for example.

Once the counter is increased, the method continues by adjusting orsetting the height and angle of a nozzle t 1020. In addition, thevelocity of the drawing head modules may be accelerated 1020 to arequired velocity V1 by acceleration rate a1, for example. The pressureapplied by a one or more pressure actuators may also be raised 1020 to arequired pressure P1, and so on. Yet, in alternate embodiments, in whichscrew-pumps are used for example, instead of raising pressure P1, ascrewing speed is raised. Next the method 1000 may proceed to act 1022at FIG. 10 b.

After adjusting or setting the nozzle, velocity and pressure, the methodcontinues by entering a delay loop 1022 until the value of timer t isequal to t1. The value of t1 may be calculated according to themechanical capabilities of the drawing-head and the length required forthe SAR or SAR segment according to the layout. When timer t value isequal to the value of t1, the acceleration rate a1 of the velocity ofthe drawing head modules may be stopped 1024 and the raising of thepressure of the pressure actuator may be stopped 1024 as well. Thus thedrawing head modules may continue drawing at velocity V1 and thepressure actuator may continue pressing at pressure P1. In alternateembodiment instead using a timer, a distant measurement D may be used.The distant measurement D may be expressed by a number of steps given toa step-motor or by feedback received from a step measurement encoderassociated to the drawing head.

While the drawing continues, the method 1000 may enter into a delay loopuntil the value of counter t is equal to t2 1026. Wherein t2 may becalculated from inputs on the drawn pattern of the SAR and the velocitythat was reached at t1. When the timer t value is equal to t2 1026, thevelocity of the drawing head modules may be decelerated 1028 to V2 atdeceleration rate a2, and the pressure by the pressure actuator may bedecreased 1028 to P2. In exemplary embodiments, the nozzle may be 1030elevated X mm and turned 1030 to an angle θ according to therequirements of the layout. Next the nozzle may be lowered 1030 Z mm(wherein Z may equal X).

The method 1000 continues by accelerating the drawing head modules to avelocity of V1 at an acceleration rate of a1, and the pressure of thepressure actuator may be raised to P1 1032. The drawing head modules maycontinue to draw 1032 the SARs according to the layout. The method 1000may then proceed to act 1034 at FIG. 10 c.

The method 1000 continues at act 1034 of FIG. 10 c by entering a delayloop until the value of the timer t is equal to t3 1034. When the timert value is equal to t3 1034, the acceleration of the velocity of thedrawing head modules and the raising of the pressure by the pressureactuator may be stopped 1036. The drawing head modules may continuedrawing at velocity V1 and the pressure actuator may continue atpressure P1 1036. Next, the method 1000 may enter a delay loop until thevalue of timer t is equal to t4 1038. When the timer t value is equal tot4 1038, the pressure imposed by the pressure actuator may be stopped1040, and the motion of the drawing head modules may be stopped 1040 aswell. The nozzle may be elevated to a desired level by raising it Y mmand spun sharply 1042 at a certain degrees (180-360 degrees for example)degree around its center, for example. The spinning of the nozzleoperates to cut the flexible material from the nozzle. In an alternateembodiment, an air-pulse may be used in order to cut the flexiblematerial from the nozzle as disclosed above in conjunction with thedescription of FIG. 8 e, for example. Yet in other embodiments, ashutter may be used as disclosed in FIGS. 8 e-8 f. In even otherexemplary embodiments, a guillotine may be utilized to cut the flexiblematerial from the nozzle, or an air knife may be used to cut theflexible material from the nozzle at once, and so on. The method 1000may then proceed to act 1044 at FIG. 10 d.

At this point in the process, the method 1000 may provide a notice orindicator 1044, such as by turning on a light, making a sound or placingtext or icons on a display as non-limiting examples, that theSurface-adhesive rule (SAR) has been drawn. Next, the method 1000determines whether all of the SARs have been drawn and the job has beenfinished 1046. If the job is finished 1046, then the method 1000 mayprovide a notice or indicator 1048, such as by turning on a light,making a sound or placing text or icons on a display for example, thatthe job as been finished and method 1000 may end. If the job has not yetbeen finished and more SARs need to be drawn 1046, then method 1000 mayreturn to act 1018 at FIG. 10 a to start drawing the next SAR.

FIG. 11 depicts a simplified diagram with relevant elements of yetanother exemplary surface-adhesive-rule technology (SART) system 1100.In an exemplary SART system 1100, the deposited flexible material may bein the form of a flexible strip 1110. The flexible strip 1110 may bepositioned in a cartridge 1118. The flexible strip 1110 may be rolled asshown in FIG. 11 or may be folded in other ways, such as a fanconfiguration. The cartridge 1118 may be associated with a rail 1114.The rail 1114 may be similar to the rail 430 described in FIG. 4 a, forexample. In some embodiments, the cartridge 1118 may be associated witha nozzle 1112. The flexible strip 1110 may be bent and/or curved duringdeposition in order to draw the desired pattern of SAR.

In some exemplary embodiments, the flexible strip 1110 may be cut by aknife 1116 when the SAR drawing reaches the end of the SAR. In alternateembodiments, other terminator-systems and techniques may be used. Thedeposited flexible strip 1110 may be bonded to the surface of the SARD'sbody (not shown in drawing) by adhesion for example.

FIG. 12 a depicts a schematic illustration of relevant elements of yetanother exemplary embodiment of a surface-adhesive-rule technology(SART) system 1200 depositing pieces of material 1212. Exemplarymaterial 1212 may be pieces of magnetic material that are to bedeposited onto a SARD's body 1220. The SART system 1200 may include amagazine 1210 in which small pieces of magnetic material 1212 arepositioned. A shear 1222 may be adapted to move in directions alongarrow 1226 and push single pieces 1218 out of the magazine 1210 to theopening of a channel 1219. In an exemplary embodiment, an applicator1216 may push the piece of material 1218 through the channel 1219 towarda SARD's body 1220 by a motor 1214. The SARD's body 1220 and/or SARTsystem 1200 may move so that a SAR 1224 is drawn by depositing thematerial 1218 onto the SARD's body 1220 in a required place.

FIG. 13 depicts a schematic illustration of relevant elements of anexemplary SARD 1300 that may be produced by SART system 1200 illustratedin FIG. 12 above. The SAR die 1300 may be comprised of a SARD body 1310and one or more SARs 1320 that are bonded to the surface of the SARDbody 1310. The SARD body 1310 may be made of iron or other magnetic orpseudo magnetic material. As such, the bonding may wholly provided bymagnetic forces, for example, or additional adhesive or bondingtechniques may be used to further strength the bond. Each SAR 1320 maybe made of a plurality of magnetic pieces 1330. The magnetic pieces 1330may be deposited adjacent to each other in accordance with the layout ofthe required SARD, thus creating a continuous SAR 1320.

In an exemplary embodiment, the pieces of material 1330 may have a sizeof approximately 1 mm cube, such as for example between 500-700 micronscube. However, it will be appreciated that the pieces of material canalso be in other sizes as well as shapes, such as rectangular cubes,trapezoids, elongated, etc. In an exemplary embodiment, a peel strengthbetween the pieces of material 1330 and the SARD's body 1310 may beabout 13 gr/mm². In some exemplary embodiments, an adhesive is providedbetween the magnetic pieces 1330 and the SARD's body 1320. Optionally,an adhesive is provided on the bottom surface of the magnetic material1330 facing the SARD's body 1320. Alternatively or additionally,adhesive is provided on the SARD's body 1320. Further, the adhesive maybe deposited on the SARD's body 1320 by a nozzle (not shown in thedrawing).

FIG. 14 a illustrates a schematic portion with relevant elements of aSARD 1400 a in accordance with yet another exemplary embodiment of thepresent disclosure. The entire surface or portions of the surface of thesurface of the SARD's body 1410 may be coated with a low surface tensionmaterial 1420. Pre-defined areas, according to the layout, of thesurface of the SARD's body 1410 may then be coated with a high surfacetension material 1415. In some embodiments, the low surface tensionmaterial 1420 can be laid on the entire surface or portions of thesurface of the SARD's body 1410 and then the high surface tensionmaterial 1415 can be laid over the low surface tension material 1420 or,the low surface tension material 1420 and the high surface tensionmaterial 1415 can be applied onto mutually exclusive surface areas ofthe SARD's body 1410.

A liquid or gel like material 1430 may be deposited on the surface ofthe SARD's body 1410, as shown in FIG. 14 b. The liquid or gel likematerial 1430 may then coalesce from the low surface tension areas tothe high surface tension areas, thereby creating one or more SARs 1440at the desired locations, as shown in FIG. 14 c.

In alternate exemplary embodiments, the liquid or gel like material 1430may be deposited only on areas surrounding the high surface tensionareas. Alternatively, liquid or gel like material 1430 may be depositedon the entire body 1410 or most of surface of the SARD's body 1410.Optionally, the liquid or gel like material 1430 may be flexiblematerial based on polymer.

The deposited liquid or gel like material 1430 will generally move tothe high surface tension area after a certain period of time (between afew minutes and 2-3 hours, for example). In exemplary embodiments theliquid or gel like material 1430 may be left at room temperature ofabout 25-30° C. Alternatively, the temperature of the deposited liquidor gel like material 1430 may be raised by about 10° C. which may reducethe time of coalescing of the liquid or gel like material 1430. Inaddition, agitators or vibrators may be used to vibrate the SARD andthereby assist in accelerating the coalescing of the material 1430.

In other exemplary embodiments the liquid or gel like material 1430 maybe hardened only after a period of time after deposition. The height ofthe created SARs 1440 may be a few millimeters, such as 700 microns-1.25mm for example. The width of the created SARs 1440 may be a fewmillimeters, such as 700 microns −1.25 mm for example.

In some exemplary embodiments of the present disclosure the surface ofthe SARD's body 1410 may be formed of or coated with a high surfacetension material and then coated or primed over this layer with a lowsurface tension material. A desired layout of the SARs may be engravedin the low surface tension coating, such that the desired layout willexpose the high surface tension material present beneath the low surfacetension coating while the rest of SARD's body 1420 will be coated with alow surface tension material. Exemplary high surface tension materialsmay include, but are not limited to, PET, Corona treated PP, Polyamideand Aluminum laminate. Exemplary low surface tension materials aresilicon, TFE or Polyethylene.

FIG. 15 depicts a schematic illustration of relevant elements of yetanother exemplary surface-adhesive-rule technology (SART) system 1500.The SART system 1500 may include an engraving mechanism 1530, a rail1550 and a nozzle 1540. The engraving mechanism 1530 may be any suitabledevice that can provide adequate engraving, such as but not limited to,a laser and/or a mechanical tool for example. The rail 1550 is suitablefor both the nozzle 1540 and the engraving mechanism 1530 to bepositioned on the surface of the rail 1540. Alternatively, theengravings may be performed in a system other then the SAR drawingsystem. In an exemplary operation of the illustrated SART system 1500,the engraving mechanism 1530 may be used to etch an area of the SARD1520 to receive a SAR pattern and then the nozzle 1540 can applymaterial for the SAR within the etched areas.

In alternate embodiment the module 1530 may be a scrapper which may beused to milled/scrap the edge of a drawn cutting SAR. In yet anotheralternate embodiment the module 1530 may be a hardening module, such asbut not limited to a light source, a air knife, etc.

FIG. 16 a depicts relevant elements of a portion of an exemplaryembodiment of a molding system 1600. Molding system 1600 may be used inthe creation a SAR counter die body and/or a SAR die body. Moldingsystem 1600 may comprise an open top mold 1602, into which gel/liquidlike material 1604 may be input. The gel/liquid like 1604 material maycomprise one or more different polymers. Exemplary polymer may be:polyurethane, monothane with shore hardness of around A30-A70 of DOWcompany, etc. Further the gel/liquid like material may comprise one ormore different additives. Exemplary additives may be accelerators suchas, but not limited to: Dibutyltin dilaurate. Other exemplary additivesmay be: silica, ceramics, metal, various fibers, different fillers. Theopen top mold 1602 may be coated with release coating (not shown indrawing). Exemplary release coating may be Cilrelease 905 of DOWCompany.

In some embodiments a flexible film 1606 may be added to be associatedto the gel/liquid like material 1604. The flexible film 1606 may be madeof different materials. Exemplary materials may be: PET (Polyethyleneterephthalate), PA (Polyamide), polypropilen, stainless steel, Aluminum(Al) and/or a combination of them, etc. In some embodiments the flexiblefilm 1606 may be added on top of the gel/liquid like material 1604,while in other embodiments it may be added at the bottom of thegel/liquid like material 1604. Furthermore the flexible film 1606 lengthmay exceed the open mold length, in these cases the open top mold 1602may have fitted apertures (not shown in drawings).

The mold with the gel/liquid like material 1604 and the flexible film1606 may pass a hardening process. Exemplary hardening may be curing byheat, curing by light (UV, infra red, visible light, etc), curing bycooling, and so on. The temperature and time of the hardening may beaccording to the gel/liquid like material's 1604 composition ofingredients and/or its dimensions. For example, hardening ofpolyurethane may be around 135 degrees Celsius for 6 hours. In alternateembodiment the hardening of polyurethane may be around 135 degreesCelsius for a few minutes if added to it are additives with highsensitivity to heat, and so on.

In some exemplary embodiments after the hardening process, the flexiblefilm 1606 may be pierced 1608. The piercing may be done by differenttechniques. Exemplary techniques may be: by a puncher, a laser, etc.

FIG. 16 b depicts relevant elements of a portion of an exemplaryembodiment of a closed molding system 1620. Closed molding system 1620may be used in the creation a SAR counter die body and/or a SAR diebody. Closed molding system 1620 may comprise a closed mold 1622, intowhich gel/liquid like material 1614 may be input with or without aflexible film 1606, similar to the one disclosed in FIG. 16 a. Closedmolding system 1620 may further comprise a lid 1626, and one or moreexcess release channels 1628. The gel/liquid like material 1614 may beinjected into the mold 1612 by extruder points in the mold 1612 (notshown in the drawing) or placed with or without a flexible film 1606inside the mold 1622 when the lid 1626 is open and only then the lid maybe placed closed 1626.

The mold with the gel/liquid like material 1614 with or without aflexible film 1606 may pass hardening process. Exemplary hardening maybe curing by heat, curing by light (UV, infra red, visible light, etc),curing by cooling, etc. The conditions and times of the hardeningtechniques may be similar to the ones disclosed in conjunction with FIG.16 a. The mold 1622 may be coated with release coating (not shown indrawing). Exemplary release coating may be Cilrelease 905 of DOWCompany. In some exemplary embodiments after the hardening process, theflexible film 1606 may be pierced 1630. The piercing may be done bydifferent techniques. Exemplary techniques may be: by a puncher, alaser, etc.

FIG. 17 a depicts relevant elements of a portion of an exemplaryembodiment of a press system 1700. Press system 1700 may be used in thecreation a SAR counter die body and/or a SAR die body. Press system 1700may comprise a base 1708, a mold 1702, and a top 1706. Top 1076 may bepart of a pressure actuator (a piston pressure actuator, for example). Aplurality of materials 1704 may be input into the mold 1702. Materials1704 such as, but not limited to: different polymers, additives, etc.Exemplary polymers may be: polyurethane, EPDM (ethylene propylene dieneMonomer rubber), silicon, acrylic, etc. Different additives may be:Graphite, Dibutyltin dilaurate, silica, ceramics, metal, various fibers,and/or different fillers.

The press process may comprise one or more phases. For example a firstphase may comprise flatting the materials 1704 as depicted in FIG. 17 bmaterial 1710. This phase may comprise heating the materials 1704 andexerting pressure on them by the top 1706, for example. The second phasemay comprise exerting higher pressure and heat and hardening thematerial. Hardening may be done by curing via light (UV, Infra red,visible light, etc), or by heating, or by cooling.

Exemplary conditions for the second phase for different materials isdisclosed in table 11 below:

TABLE 11 Material Type Temperature [C.] Pressure [bar] Time [sec] EPDM135 5 30 Silicon 180 8 12

FIG. 17 c depicts relevant elements of a portion of an exemplaryembodiment of an injection/extruder molding system 1720.Injection/extruder molding system 1720 may be used in the creation a SARcounter die body and/or a SAR die body. Injection/extruder moldingsystem 1720 may comprise: a closed mold 1712, one or more injectingapertures 1722, one or more excess release channels 1718. Liquid/gellike material may be heated and injected 1720 with pressure to theclosed mold 1712 via the one or more injecting apertures 1722. TheLiquid/gel like material may be different polymers, additives, etc.Exemplary polymers may be: polyurethane, EPDM (ethylene propylene dieneMonomer rubber), silicon, acrylic, etc. Different additives may be:Graphite, Dibutyltin dilaurate, silica, ceramics, metal, various fibers,different fillers, etc. The mold 1712 may be coated with release coating(not shown in drawing). Exemplary release coating may be Cilrelease 905of DOW Company. Next a hardening process may be implemented. Hardeningmay be done by curing via light (UV, Infra red, visible light, etc), orby heating, or by cooling. Exemplary conditions for the hardening fordifferent materials are disclosed in table 11 above.

FIG. 18 depicts relevant elements of a portion of an exemplaryembodiment of a coating system 1800. Coating system 1800 may be used inthe creation a SAR counter die body and/or a SAR die's body. Exemplaryliquid/gel-like material that may be used in the coating system 1800 maybe different polymers with different additives. Exemplary polymers maybe silicon, acrylic, etc. Exemplary additives can be: Graphite,Dibutyltin dilaurate, silica, ceramics, metal, various fibers, and/ordifferent fillers. In some embodiments the liquid/gel-like material maybe solvent base. Exemplary solvent may be: MEK (Methyl Ethyl Ketone),Toluene, etc.

Coating system 1800 may comprise: an un-winder 1802, a coating head1806, a chamber 1808, and a winder 1812. Chamber 1808 may comprise anoven, a light radiator, and or a cooling mechanism, for example. On theun-winder 1802 a film 1810 may be winded. The film may be a PET(Polyethylene terephthalate), PA (Polyamide), polypropilen, stainlesssteel, Aluminum (Al) and/or a combination of them, etc. Winder 1812 maypull and wind the film on the other end of the coating system 1800. Thefilm may then pass the coating head 1806. The coating head 1806 may coatthe film with a layer of the liquid/gel-like material 1811. Next thecoated film may pass through a chamber 1808 for hardening. In someembodiments there may not be a need for the chamber 1808. The coated andhardened film may pass through a surface treatment (not shown in thedrawing). Exemplary surface treatment may be polish, grinding, scarping,etc. The coated and hardened film may then be winded on the winder 1812,for example.

In some exemplary embodiments there may be one or more coating heads1806 one or more chambers 1808. In other exemplary embodiments thecoated film may pass in a loop through the coating heads 1806 one ormore chambers 1808. The one or more coating heads 1806 may comprisedifferent liquid/gel-like material 1811.

In exemplary embodiments the creation a SAR counter die's body and/or aSAR die's body may be implemented in one or more different methods(molding, press, coating, etc) and/or a combination of them. In some ofthe molding techniques a negative pattern may be used inside the mold inorder to create a required pattern and/or layout for the SAR counterdie's body and/or a SAR die's body.

Other exemplary embodiments may use a thermoplastic material for thecreation a SAR counter die's body. In such embodiments an additionalphase may be added in the creation. The additional phase may compriseimprinting the SARs on the thermoplastic material at a requiredtemperature. Exemplary temperature may be around 69 C degree forexample.

FIG. 19 is a functional block diagram of the components of an exemplaryembodiment of system or sub-system operating as a controller orprocessor 1900 that could be used in various embodiments of thedisclosure for controlling aspects of the various embodiments. It willbe appreciated that not all of the components illustrated in FIG. 19 arerequired in all embodiments of the activity monitor but, each of thecomponents are presented and described in conjunction with FIG. 19 toprovide a complete and overall understanding of the components. Thecontroller can include a general computing platform 1900 illustrated asincluding a processor/memory device 1902/1904 that may be integratedwith each other or, communicatively connected over a bus or similarinterface 1906. The processor 1902 can be a variety of processor typesincluding microprocessors, micro-controllers, programmable arrays,custom IC's etc. and may also include single or multiple processors withor without accelerators or the like. The memory element of 1904 mayinclude a variety of structures, including but not limited to RAM, ROM,magnetic media, optical media, bubble memory, FLASH memory, EPROM,EEPROM, etc. The processor 1902, or other components in the controllermay also provide components such as a real-time clock, analog to digitalconvertors, digital to analog convertors, etc. The processor 1902 alsointerfaces to a variety of elements including a control interface 1912,a display adapter 1908, an audio adapter 1910, and network/deviceinterface 1914. The control interface 1912 provides an interface toexternal controls, such as sensors, actuators, drawing heads, nozzles,cartridges, pressure actuators, leading mechanism, drums, step motors, akeyboard, a mouse, a pin pad, an audio activated device, as well as avariety of the many other available input and output devices or, anothercomputer or processing device or the like. The display adapter 1908 canbe used to drive a variety of alert elements 1916, such as displaydevices including an LED display, LCD display, one or more LEDs or otherdisplay devices. The audio adapter 1910 interfaces to and drives anotheralert element 1918, such as a speaker or speaker system, buzzer, bell,etc. The network/interface 1914 may interface to a network 1920 whichmay be any type of network including, but not limited to the Internet, aglobal network, a wide area network, a local area network, a wirednetwork, a wireless network or any other network type including hybrids.Through the network 1920, or even directly, the controller 1900 caninterface to other devices or computing platforms such as one or moreservers 1922 and/or third party systems 1924. A battery or power sourceprovides power for the controller 1900.

In the description and claims of the present disclosure, each of theverbs, “comprise”, “include” and “have”, and conjugates thereof, areused to indicate that the object or objects of the verb are notnecessarily a complete listing of members, components, elements, orparts of the subject or subjects of the verb and further, all of thelisted objects are not necessarily required in all embodiments.

As used herein, the singular form “a”, “an” and “the” include pluralreferences unless the context clearly dictates otherwise. For example,the term “a material” or “at least one material” may include a pluralityof materials, including mixtures thereof.

In this disclosure the words “unit”, “element”, and/or “module” are usedinterchangeably. Anything designated as a unit, element, and/or modulemay be a stand-alone unit or a specialized module. A unit, element,and/or module may be modular or have modular aspects allowing it to beeasily removed and replaced with another similar unit, element, and/ormodule. Each unit, element, and/or module may be any one of, or anycombination of, software, hardware, and/or firmware. Software of alogical module can be embodied on a computer readable medium such as aread/write hard disc, CDROM, Flash memory, ROM, etc. In order to executea certain task a software program can be loaded to an appropriateprocessor as needed.

The present disclosure has been described using detailed descriptions ofembodiments thereof that are provided by way of example and are notintended to limit the scope of the disclosure. The described embodimentscomprise different features, not all of which are required in allembodiments of the disclosure. Some embodiments of the presentdisclosure utilize only some of the features or possible combinations ofthe features. Many other ramifications and variations are possiblewithin the teaching of the embodiments comprising different combinationsof features noted in the described embodiments.

It is appreciated that certain features of the invention, which are, forclarity, described in the context of separate embodiments, may also beprovided in combination in a single embodiment. Conversely, variousfeatures of the invention, which are, for brevity, described in thecontext of a single embodiment, may also be provided separately or inany suitable sub-combination or as suitable in any other describedembodiment of the invention.

It will be appreciated by persons skilled in the art that the presentdisclosure is not limited by what has been particularly shown anddescribed herein above. Rather the scope of the disclosure is defined bythe claims that follow.

1-27. (canceled)
 28. A rule die comprising: a die body having a broad surface; and a plurality of elongate rules protruding above said broad surface of said die body in order that, when a cardboard workpiece is subjected to compression between the die and a counter die, said rules deform a surface of said workpiece facing the die to form elongate depressions therein, said rules being surface adhesive rules formed of a polymeric material and bonded to said broad surface, each rule of said rules having a respective first elongate surface facing said broad surface and bonded thereto, and a respective second elongate surface contiguous with said first elongate surface, which second elongate surface protrudes above said broad surface such that at least a region of said rule furthest remote from said broad surface contacts said surface of said workpiece during said compression.
 29. The rule die of claim 28, said die body including a film substrate forming at least a portion of said broad surface, which substrate being sufficiently flexible to be capable of being wrapped around a drum of a die base, from an initial flat configuration.
 30. The rule die of claim 29, said film substrate including a layer selected from the group consisting of an aluminum layer and a stainless steel layer.
 31. The rule die of claim 29, wherein the film substrate includes a layer of polymeric material.
 32. The rule die of claim 31, wherein said polymeric material in said film substrate includes at least one material selected from the group consisting of polyester, polycarbonate, polyethylene terephthalate, polyamide, and polypropylene.
 33. The rule die of claim 28, wherein each said rule is bonded to said broad surface of said film substrate by means of an intermediate adhesive material.
 34. The rule die of claim 28, wherein at least one said rule includes at least two layers made of different materials.
 35. The rule die of claim 28, said region having an asymmetrical cross-section.
 36. The rule die of claim 28, said region having a rectangular cross-section.
 37. The rule die of claim 28, said region having a trapezoidal cross-section.
 38. The rule die of claim 28, said region having a rounded cross-section.
 39. The rule die of claim 28, said region having a triangular cross-section.
 40. The rule die of claim 28, a height of said rule being within a range of 700 microns to 1250 microns, and a width of said rule being within a range of 700 microns to 1250 microns.
 41. The rule die of claim 31, a height of said rule being up to several millimeters.
 42. The rule die of claim 31, a width of said rule being within a range of 700 microns to 1250 microns.
 43. An apparatus for treating a cardboard workpiece, the apparatus comprising: (a) a counter die; and (b) a rule die disposed generally opposite said counter die, said rule die including: a die body having a broad surface; and a plurality of elongate rules protruding above said broad surface of said die body in order that, when the cardboard workpiece is subjected to compression between said rule die and said counter die, said rules deform a first surface of the cardboard workpiece facing the die to form elongate depressions therein, said rules being surface adhesive rules formed of a polymeric material and bonded to said broad surface, each rule of said rules having a respective first elongate surface facing said broad surface and bonded thereto, and a respective second elongate surface contiguous with said first elongate surface, which second elongate surface protrudes above said broad surface such that at least a region of said rule furthest remote from said broad surface contacts said first surface of the cardboard workpiece during said compression.
 44. The apparatus of claim 43, said counter die having a base and a resilient layer overlying and attached to said base, which layer comprises at least one polymer.
 45. The apparatus of claim 43, said counter die having a blank counter surface disposed opposite each of said rules, such that when the cardboard workpiece is subjected to said compression between said rule die and said counter die, said blank counter surface oppose said rules.
 46. The apparatus of claim 43, said counter die having a base and a resilient layer overlying and attached to said base, said layer and said base both comprising at least one polymer.
 47. The apparatus of claim 44, said resilient layer selected to be adaptive to a protrusion of said rules during said compression between said rule die and said counter die.
 48. The apparatus of claim 43, said counter die including a polymer selected from the group consisting of polyurethane, ethylene propylene diene monomer (EPDM) rubber, nitrile butadiene rubber (NBR), acrylic rubber, silicone rubber, and styrene butadiene rubber (SBR).
 49. An apparatus for treating a cardboard workpiece, the apparatus comprising: (a) a counter die; and (b) a rule die disposed generally opposite said counter die, said rule die including: a die body having a broad surface; and a plurality of elongate rules protruding above said broad surface of said die body in order that, when the cardboard workpiece undergoes compression between said rule die and said counter die, said rules deform a first surface of the cardboard workpiece facing the die to form elongate depressions therein, said rules being surface adhesive rules formed of a polymeric material and bonded to said broad surface, each rule of said rules having a respective first surface facing said broad surface and bonded thereto, and a respective second elongate surface, which second elongate surface protrudes above said broad surface such that at least a region of said rule furthest remote from said broad surface contacts said first surface of the cardboard workpiece during formation of said elongate depressions, said counter die having a blank counter surface disposed opposite each of said elongate rules, such that when the cardboard workpiece undergoes said compression between said rule die and said counter die, said blank counter surface opposes said elongate rules. 